Removing nozzles (4A-FE, 7A-FE)
1. Disconnect (-) wire from the negative battery terminal.
Note: See section above for removal and installation parts "Gasoline engines 4A-FE, 7A-FE".
2. Drain the coolant.
3. Disconnect the hoses from the air cleaner.
4. (Except 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. (Only for serial version of the engine) Remove the engine lifting hook and intake manifold top bracket.
- A) Remove the bolt (or bolts) and remove the air tube and fuel hose.
- b) After unscrewing the bolt and nut, remove the engine lifting hook and upper intake manifold bracket with gasket.
8. (Only for serial version of the engine) Remove the air intake chamber cover.
- A) Disconnect 2 crankcase ventilation hoses.
- b) Disconnect the intake manifold absolute pressure sensor hose.
- V) Using a 6mm socket wrench, remove the 3 bolts and 2 nuts and remove the intake manifold top cover along with the gasket.
9. Disconnect the fuel return hose from the fuel pressure regulator.
10. Having unscrewed 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 off 3 or 2 (lean-burn combustion option) bolts and remove the fuel manifold with injectors.
Note: Be careful not to drop the injectors when removing the fuel manifold.
- b) Remove 4 insulators and 2 or 3 (lean-burn combustion option) spacers from the cylinder head.
- V) Remove the injectors from the fuel manifold.
- G) Remove the O-rings and safety bushings from each nozzle.
Removing nozzles (3S-FE, 4S-FE)
1. Disconnect (-) wire from the negative battery terminal.
2. Remove the throttle body.
3. Remove the left engine hoist bracket and intake manifold bracket No. 2 by unscrewing the bolt and nut.
4. (Models with exhaust gas recirculation) Remove the EGR valve and pipe.
- A) Disconnect the vacuum hose from the EGR valve (1) and EGR hose (2).
- b) Loosen the EGR pipe nut on the cylinder head side.
- V) Remove the 2 nuts and remove the EGR valve, tube assembly and gasket.
5. Remove the 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 fluctuation damper.
- V) Remove the damper and 2 gaskets, disconnect the inlet fuel hose from the fuel manifold.
- G) 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.
- V) Disconnect the injector connectors.
- G) Remove the 2 bolts connecting the fuel manifold to the cylinder head.
- d) Remove the fuel manifold with injectors as shown.
Note: handle nozzles carefully and do not let them fall.
- e) Remove the four insulators and two spacers from the cylinder head.
- and) Remove the four injectors from the fuel manifold.
- h) Remove the o-ring and o-ring from each injector.
Removing nozzles (3S-GE)
1. Disconnect (-) wire from the negative battery terminal.
2. Drain the coolant (see chapter "Cooling system").
3. (Models with automatic transmission) Disconnect the throttle control cable from the throttle actuator.
4. Disconnect the accelerator cable from the throttle actuator mechanism.
5. Disconnect the air filter cover and air filter hose.
6. Disconnect the cold start injector tube.
7. Disconnect the following hoses from the throttle body and intake plenum:
Note: put labels on the hoses for subsequent correct connection.
- A) Crankcase ventilation hose.
- b) Vacuum hose from the thermally controlled valve of the fuel vapor recovery system.
- V) Coolant bypass hoses.
- G) Vacuum and air hoses from the air pipeline.
- d) Brake booster hose from bypass tube.
8. Remove the intake plenum bracket,
- A) Turn away four bolts and remove an inlet chamber bracket.
- b) Remove the bolt holding the intake plenum and bracket.
- V) Remove the five bolts and two nuts and remove the intake plenum 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 power steering pump.
- V) Vacuum hoses from the electro-pneumatic valve of the fuel control system.
- G) Vacuum hose from the electro-pneumatic valve of the intake manifold geometry change system.
- d) Vacuum hose from the vacuum receiver.
- V) Vacuum hose from the intake manifold absolute pressure sensor.
- and) Vacuum hoses from the power drive of the air conditioner.
11. Disconnect the connectors and connection with "earth".
- A) Electropneumatic valve of the fuel supply control system.
- b) Electropneumatic valve system with variable intake manifold geometry.
- V) Connection with "earth".
12. Remove the air control valve assembly by removing the three bolts.
13. Remove the intake manifold along with the gasket by unscrewing the four bolts and three nuts.
14. Remove the cold start injector tube from the fuel manifold, along with two gaskets, by unscrewing the bypass bolt.
15. Disconnect the fuel inlet hose from the fuel manifold by removing the bypass bolt and two gaskets.
16. Disconnect the injector connectors.
17 Remove the wire harness guard by removing the two nuts.
18. Remove the fuel manifold and injectors.
- A) Turn away three bolts and remove a fuel manifold together with atomizers.
Note; handle nozzles carefully and do not let them fall.
- b) Remove the four insulators and three spacers from the cylinder head
- V) Carefully remove by turning. four injectors from the fuel manifold.
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 tube.
5. Disconnect the fuel supply pipe from the inlet fuel line by unscrewing the bypass bolt and removing the two gaskets.
Note: place a suitable container or place a rag under the fuel line.
6. Disconnect motor wiring:
- A) Loosen the bolt, removing the wire harness guard.
- 6) Disconnect the four injector connectors.
7. Remove the upper intake manifold strut by removing the bolt and nut.
8. Remove a fuel collector together with atomizers.
- A) Unscrew the two bolts and remove the fuel manifold along with the four injectors.
Note: handle nozzles carefully and do not let them fall.
- b) Remove the four injectors from the fuel manifold.
- V) Remove the four insulators and two spacers from the cylinder head.
