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Installation [10/2017 - ]: Procedure

  1. INSTALL STUD BOLT 

    HINT: 

    If a stud bolt is deformed or the threads are damaged, replace it.

    1. Using an E8 "TORX" socket wrench, install the 2 stud bolts to the intake manifold.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

  2. INSTALL INTAKE MANIFOLD 
    1. Set 2 new No. 1 intake manifolds to head gaskets on each cylinder head as shown in the illustration.
      NOTE:
      • Align the port holes of the gasket, cylinder head sub-assembly and cylinder head LH.
      • Be careful of the installation direction.
      GTY832470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion
    2. Set the intake manifold on the cylinder head sub-assembly and cylinder head LH.
    3. Install and uniformly tighten the 4 bolts and 4 nuts.

      Torque: 21 N.m (214 kgf/cm, 15 ft.lbf) 

  3. INSTALL EGR VALVE ASSEMBLY 

    Refer to PROCEDURE - Step 1

  4. CONNECT WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 3

  5. CONNECT NO. 15 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 2

  6. CONNECT GENERATOR CABLE AND MOTOR CABLE 

    Refer to PROCEDURE - Step 4

  7. INSTALL FUEL DELIVERY WITH SENSOR PIPE ASSEMBLY 

    Refer to PROCEDURE - Step 2 [10/2017 - 10/2020] , or refer to PROCEDURE - Step 2 [10/2020 - ]

  8. CONNECT WIRE HARNESS 

    Refer to PROCEDURE - Step 3 [10/2017 - 10/2020] , or refer to PROCEDURE - Step 3 [10/2020 - ]

  9. INSTALL FUEL TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 6 [10/2017 - 10/2020] , or refer to PROCEDURE - Step 6 [10/2020 - ]

  10. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5 [10/2017 - 10/2020] , or refer to PROCEDURE - Step 5 [10/2020 - ]

  11. INSTALL INTAKE AIR SURGE TANK ASSEMBLY 
    NOTE:

    Do not apply oil to the bolts and nuts as listed below:

    Oil Application Prohibited Bolt and Nut
    Bolt and Nut for Intake Air Surge Tank Assembly and Intake Manifold
    Bolt for No. 2 Surge Tank Stay and Intake Air Surge Tank Assembly
    1. Install a new air surge tank to intake manifold gasket to the intake air surge tank assembly.
    2. Set the intake air surge tank assembly on the intake manifold.
    3. Install and uniformly tighten the 5 bolts and 2 nuts.

      Torque: 21 N.m (214 kgf/cm, 15 ft.lbf) 

    4. Install the No. 2 surge tank stay to the intake air surge tank assembly and camshaft housing sub-assembly LH with the 2 bolts.

      Torque: 21 N.m (214 kgf/cm, 15 ft.lbf) 

    5. Connect the PCV hose to the intake air surge tank assembly, and slide the clamp to secure the hose.
    6. Attach the 2 clamps to connect the transmission breather assembly.
    7. Attach the clamp to connect the No. 1 fuel tube sub-assembly.
    8. Connect the wire harness with the bolt.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

    9. Attach the 3 clamps.
    10. Connect the vacuum sensor connector.
    11. Connect the purge VSV to the intake air surge tank assembly with the bolt.

      Torque: 21 N.m (214 kgf/cm, 15 ft.lbf) 

    12. Connect the No. 1 fuel vapor feed hose to the intake air surge tank assembly.
    13. Connect the purge VSV connector.
  12. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to INSTALLATION [10/2017 - ]

  13. INSPECT FOR FUEL LEAK 

    Refer to PROCEDURE - Step 1

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