- A) Install a new sealing sleeve on the injector (if filmed).
- b) Apply a thin layer of fuel (lithol) on a new O-ring and install it on the injector.
- V) Rotate the injectors and insert them into the fuel manifold.
- G) Install (better stick it) four insulators and two or three (4A-FE with Lean bum) spacers.
- d) Install the injectors together with the fuel manifold on the intake manifold. Gradually tighten the fuel rail to intake manifold bolts.
3S-GE, 4A-FE, ZA-FE | 3S-FE, 4S-FE |
- e) Make sure the injectors turn without sticking in their seats.
Note: If the nozzles do not rotate, the O-rings cannot be installed incorrectly. Replace o-rings.
- and) Install the injectors so that their connectors are on top.
- h) Bolt the fuel manifold to the cylinder head. Tightening torque: 17 Nm.
2. Connect the electrical connectors of the injectors.
Note: (3S-GE) when connecting, do not mix up the connectors corresponding to the cylinders, especially 1 and 2, as well as 3 and 4.
4A-FE, 7A-FE
1. Connect the fuel inlet hose to the fuel manifold: install the bypass bolt (with 2 new gaskets) and tighten it. Tightening torque: 29 N.m.
2. Connect the fuel return pipe to the fuel pressure regulator.
3 (Only for serial version of the engine) Install the intake manifold top.
Install a new gasket and use a 6mm socket wrench to tighten the 3 bolts and 2 nuts in the sequence shown in the illustration. Tightening torque: 19 N.m
4. Connect the crankcase ventilation hoses.
5. Connect the intake manifold absolute pressure sensor hose.
6. fOnly for the standard version of the engine) Install the upper intake manifold strut.
- A) Lay a new gasket on top of the intake manifold flange with the tab on the gasket facing down.
- b) Attach the upper intake manifold strut and transport hook (eye) engine bolt and nut. Tightening torque: 28 Nm
Note: Use a new bolt and a new nut.
- V) Secure the air bypass tube and fuel inlet hose with the bolt (or 2 bolts).
7. Install the throttle body.
8. (Except left hand drive models for lean mixture) Connect the accelerator cable to the throttle body.
9. (Models with automatic transmission with a serial engine option). Connect the throttle cable to the throttle body.
10. Install the air filter hose.
11. Fill the cooling system with coolant.
3S-FE, 4S-FE
1. Connect the vacuum hose to the fuel pressure regulator.
2. Install the two wire harness clamps to the brackets on the intake manifold.
3. Connect the fuel return hose to the fuel return tube.
4. Connect the fuel inlet hose to the intake manifold.
- A) Temporarily connect the fuel inlet hose and fuel pressure oscillation damper using 2 new gaskets.
- b) Tighten the vibration damper. Tightening torque: 34 Nm.
5. Install the cylinder head cover (see section "cylinder head").
6. Install intake manifold bracket No. 1 by tightening the two bolts. Tightening torque: 42 Nm.
7. (Models with exhaust gas recirculation) Install the solenoid valve and EGR pipe.
- A) Install a new gasket, valve and tube assembly using the bypass bolt and 2 nuts.
Torque:
- nuts: 13 N.m
- bolts: 59 N.m
- b) Connect the vacuum hose to the EGR valve (1) (from port E of electropneumatic valve) and EGR hose (2) (from pressure modulator).
8. Install intake manifold bracket #2 and left engine lift bracket with bolt and nut. Tightening torque: 42 Nm.
9. Install the throttle body.
3S-GE
1 Install the wire harness guard with two nuts.
2 Connect the fuel inlet hose to the fuel manifold with a bypass bolt and two new gaskets.
3. Install the cold start injector fuel line with the bypass bolt.
4. Install the intake manifold using a new gasket, four bolts and three nuts. Tightening torque: 19 Nm.
5. Install the air control valve assembly with the three bolts.
6. Connect the connectors and connect with "earth".
- A) Electropneumatic fuel control valve.
- b) Electropneumatic valve system with variable intake manifold geometry.
- V) Connection with "earth".
7. Connect the following hoses to the air line:
- A) Vacuum hose from the fuel pressure regulator.
- b) Vacuum hoses from power steering pump.
- V) Vacuum hoses from the electro-pneumatic fuel control valve.
- G) Vacuum hose from the electro-pneumatic valve of the system with variable intake manifold geometry.
- d) Vacuum hose from the vacuum receiver.
- e) Vacuum hose from the intake manifold absolute pressure sensor.
- and) Vacuum hoses from the power drive of the air conditioner.
8. Install the intake manifold bracket with two bolts and a nut. Tightening torque 39: Nm.
9. Install the inlet chamber.
- A) Install a new gasket and secure the intake plenum with five bolts and two nuts. Tightening torque: 19 Nm.
- b) Install and tighten the bolt connecting the intake plenum and bracket. Tightening torque: 39 Nm.
- V) Install the intake plenum bracket and secure it with four bolts. Tightening torque: 19 Nm.
10. Connect the following hoses to the throttle body and intake manifold top:
- A) Vacuum and air hoses from the air pipeline.
- b) Brake booster hose from bypass tube.
- V) Crankcase ventilation hose.
- G) (Models with catalytic converter) Vacuum hose from the bimetal valve of the emission control system
- d) Coolant bypass hose from the cooling system outlet.
- e) Coolant bypass hose from coolant bypass tube.
11. Connect the cold start injector tube.
12. Connect the air filter cover and air filter hose.
13. Connect the accelerator cable and adjust if necessary.
14. (Models with automatic transmission) Connect the throttle cable and adjust if necessary.
15. Fill with coolant (see chapter "Cooling system")
5E-FE
2. Install the upper intake manifold bracket by tightening the bolts and nuts. Tightening torque: 17 Nm.
3. Connect motor wiring.
- A) Connect the four injector connectors.
- b) Install wire harness guard.
4. Attach the fuel inlet hose to the fuel manifold using two new gaskets and a bypass bolt. Tightening torque: 29 Nm.
5. Connect the fuel return hose to the fuel return tube.
6. Connect the vacuum hose to the fuel pressure regulator.
7. Connect the crankcase ventilation hoses.
8. Connect (-) negative battery cable.
9. Check for possible fuel leakage through the connections.
All engines
10. Connect (-) negative battery cable.