Removal fuel injectors [Toyota Corona T190]

Removal injectors (4A-FE, 7A-FE)

1. Disconnect the (-) cable from the negative battery terminal.

Note: For removal and installation details, see above in the section "Petrol engines 4A-FE, 7A-FE".

2. Drain the coolant.

3. Disconnect the hoses from the air cleaner.

4. (Except for models with Lean Bum system) Disconnect the accelerator cable from the throttle actuator.

5. (Models with automatic transmission) Disconnect the throttle valve control cable from the throttle actuator

6. Remove the throttle body.

7. (For serial engine version only) Remove the engine lift hook and upper intake manifold bracket.

• a) Loosen the bolt(s) and remove the air tube and fuel hose.
• b) After unscrewing the bolt and nut, remove the engine lifting hook and the bracket of the upper part of the intake manifold with the gasket.

8. (For serial engine version only) Remove the air intake chamber cover.

• a) Disconnect the 2 crankcase ventilation hoses.

• b) Disconnect the manifold absolute pressure sensor hose.
• c) Using a 6 mm socket wrench, unscrew the 3 bolts and 2 nuts and remove the upper intake manifold cover together with the gasket.

9. Disconnect the fuel return hose from the fuel pressure regulator.





10. After unscrewing the bypass bolt with gaskets, disconnect the fuel supply pipe from the fuel manifold



11. Disconnect the injector connectors.

12. Remove the fuel manifold and injectors.

• a) Turning 3 or 2 (option with a lean mixture combustion system) bolts and remove the fuel manifold together with the injectors.

Note: Be careful not to drop the injectors when removing the fuel rail.

• b) Remove 4 insulators and 2 or 3 (option with a lean mixture combustion system) spacers from the cylinder head.
• c) Remove the injectors from the fuel manifold.
• d) Remove the O-rings and protective sleeves from each injector.

Removal injectors (3S-FE, 4S-FE)

1. Disconnect the (-) cable from the negative battery terminal.

2. Remove the throttle body.

3. Remove the left engine lift bracket and intake manifold bracket No.2 by unscrewing the bolt and nut.

4. (Models with EGR system) Remove the EGR valve and tube.

• a) Disconnect the vacuum hose (1) and the EGR hose (2) from the EGR valve.

• b) Loosen the EGR pipe nut on the cylinder head side.
• c) Unscrew the 2 nuts and remove the EGR valve, the pipe assembly and the gasket.

5. Remove intake manifold bracket No.1 by unscrewing 2 bolts.

6. Remove the cylinder head cover.

7. Disconnect the fuel inlet hose and fuel return hose.

• a) Disconnect the engine wiring clamp from the wiring bracket.
• b) Loosen the fuel pressure damper.
• c) Remove the damper and 2 gaskets, disconnect the fuel inlet hose from the fuel manifold.
• d) Disconnect the fuel return hose from the fuel return pipe.

8. Remove the fuel manifold and injectors.

• a) Disconnect the 2 engine wiring clamps from the wiring brackets on the intake manifold.
• b) Disconnect the vacuum hose from the fuel pressure regulator.

• c) Disconnect the injector connectors.

• d) Unscrew the 2 bolts connecting the fuel manifold to the cylinder head.

• d) Remove the fuel manifold together with the injectors as shown in the figure.

Note: Handle the nozzles carefully and do not allow them to fall.

• e) Remove four insulators and two spacers from the cylinder head.

• g) Remove the four injectors from the fuel manifold.
• h) Remove the O-ring and sealing sleeve from each injector.

Removal injectors (3S-GE)

1. Disconnect the (-) cable from the negative battery terminal.

2. Drain the coolant (see chapter "Cooling system").



3. (Models with automatic transmission) Disconnect the throttle valve control cable from the throttle actuator mechanism.

4. Disconnect the accelerator cable from the throttle actuator.

5. Disconnect the air filter cover and air filter hose.

6. Disconnect the cold start injector pipe.

7. Disconnect the following hoses from the throttle body and intake plenum:

Note: Place marks on the hoses to ensure correct connection later.

• a) Crankcase ventilation hose.
• b) Vacuum hose from the temperature-controlled valve of the fuel vapor recovery system.
• c) Coolant bypass hoses.

• d) Vacuum and air hoses from the air pipeline.
• d) Brake booster hose from the bypass pipe.

8. Remove the intake chamber bracket,

• a) Unscrew the four bolts and remove the intake chamber bracket.

• b) Remove the bolt holding the intake chamber and bracket.
• c) Unscrew the five bolts and two nuts and remove the intake chamber and gasket.

9. Remove the intake manifold bracket



10. Disconnect the following hoses from the air line.

• a) Vacuum hose from the fuel pressure regulator.
• b) Vacuum hoses from the power steering pump.
• c) Vacuum hoses from the electropneumatic valve of the fuel supply control system.
• d) Vacuum hose from the electropneumatic valve of the intake manifold geometry change system.
• d) Vacuum hose from the vacuum receiver.
• c) Vacuum hose from the absolute pressure sensor in the intake manifold.
• g) Vacuum hoses from the air conditioner power drive.

11. Disconnect the connectors and ground connection.

• a) Electro-pneumatic valve of the fuel supply control system.
• b) Electro-pneumatic valve of the system with variable geometry of the intake manifold.
• c) Connection to ground.

The original can be viewed on the website www.ToyotaMAN.ru



12. Remove the air control valve assembly by unscrewing the three bolts.



13. Remove the intake manifold together with the gasket by unscrewing four bolts and three nuts.

14. Remove the cold start injector pipe from the fuel manifold together with two gaskets by unscrewing the bypass bolt.

15. Disconnect the fuel inlet hose from the fuel rail by removing the bypass bolt and two gaskets.



16. Disconnect the injector connectors.

17 Remove the wiring harness protector by unscrewing the two nuts.



18. Remove the fuel manifold and injectors.

• a) Unscrew the three bolts and remove the fuel manifold together with the injectors.

Note; handle the nozzles with care and do not allow them to fall.

• b) Remove four insulators and three spacers from the cylinder head
• c) Carefully remove the four injectors from the fuel manifold by turning them.

5E-FE

2. Remove the crankcase ventilation hose

3. Disconnect the vacuum hose from the fuel pressure regulator.

4. Disconnect the fuel return hose from the fuel return pipe.

5. Disconnect the fuel supply pipe from the fuel inlet pipe by unscrewing the bypass bolt and removing the two gaskets.

Note: Place a suitable container or rag under the fuel line.

6. Disconnect the engine wiring:

• a) Unscrew the bolt, removing the wiring harness protection.

• 6) Disconnect the four injector connectors.

7. Remove the upper intake manifold support by unscrewing the bolt and nut.



8. Remove the fuel manifold together with the injectors.

• a) Unscrew the two bolts and remove the fuel manifold together with the four injectors.

Note: Handle the nozzles carefully and do not allow them to fall.

• b) Remove the four injectors from the fuel rail.
• c) Remove four insulators and two spacers from the cylinder head.