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Installation [10/2015 - ]: Procedure

  1. INSTALL STUD BOLT 

    HINT: 

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

    1. Using an E6 "TORX" socket wrench, install the stud bolt to the intake manifold.

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

      GTY650204Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET 
    1. Install 2 new No. 1 intake manifold to head gaskets to the cylinder head sub-assembly LH and cylinder head sub-assembly RH.
      NOTE:
      • Align the port holes of the No. 1 intake manifold to head gaskets and cylinder head sub-assembly LH and cylinder head sub-assembly RH.
      • Make sure that the No. 1 intake manifold to head gaskets are installed in the correct direction.
  3. INSTALL INTAKE MANIFOLD 
    1. Temporarily install the intake manifold to the cylinder head sub-assembly LH and cylinder head sub-assembly RH with the 4 bolts and 4 nuts.
    2. Tighten the 4 bolts and 4 nuts in the order shown in the illustration.

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

      GTY646785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
  4. INSTALL INJECTOR VIBRATION INSULATOR 

    Refer to PROCEDURE - Step 2 [10/2015 - 03/2018] , or refer to PROCEDURE - Step 2 [03/2018 - ]

  5. INSTALL NO. 1 DELIVERY PIPE SPACER 

    Refer to PROCEDURE - Step 3 [10/2015 - 03/2018] , or refer to PROCEDURE - Step 3 [03/2018 - ]

  6. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4 [10/2015 - 03/2018] , or refer to PROCEDURE - Step 4 [03/2018 - ]

  7. CONNECT FUEL TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5 [10/2015 - 03/2018] , or refer to PROCEDURE - Step 5 [03/2018 - ]

  8. INSTALL NO. 2 EGR PIPE GASKET 
    1. Install a new No. 2 EGR pipe gasket to the No. 2 EGR pipe.
      GTY677180Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Claw
      NOTE:

      Make sure that the No. 2 EGR pipe gasket is installed in the correct direction.

    2. Install a new No. 2 EGR pipe gasket to the EGR valve assembly.
      NOTE:

      Make sure that the No. 2 EGR pipe gasket is installed in the correct direction.

      GTY623412Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Claw
  9. INSTALL NO. 2 EGR PIPE 
    1. Set the No. 2 EGR pipe.
    2. Using an E6 "TORX" socket wrench, install the stud bolt to the intake manifold.

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

    3. Install the No. 2 EGR pipe to the intake manifold and EGR valve assembly with the 2 bolts and 2 nuts in the order shown in the illustration.

      Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) 

      Fig 1: No. 2 EGR Pipe Tightening Sequence
      GTY673592Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
  10. INSTALL NO. 2 ENGINE MOUNTING STAY RH 
    1. Install the No. 2 engine mounting stay RH to the intake manifold with the bolt.

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

    2. Install the No. 2 engine mounting stay RH to the engine mounting insulator sub-assembly RH with the bolt and 2 nuts.

      Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

    3. Connect the wire harness clamp bracket to the No. 2 engine mounting stay RH with the bolt.

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

    4. Connect the EGR valve assembly connector.
      GTY619522Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Fuel Tube Sub-assembly Connector
      *b EGR Valve Assembly Connector
    5. Connect the fuel tube sub-assembly connector.
    6. Engage the wire harness clamp to the wire harness clamp bracket.
  11. INSTALL RESERVOIR BRACKET 

    Refer to PROCEDURE - Step 11 [10/2015 - 03/2018] , or refer to PROCEDURE - Step 11 [03/2018 - ]

  12. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 
    1. Install the brake master cylinder reservoir assembly to the reservoir bracket with the 2 nuts.

      Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

      GTY615109Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Brake Master Cylinder Reservoir Assembly Connector
      *b Air Conditioner Pressure Sensor Connector
    2. Engage the 2 clamps to install the wire harness to the brake master cylinder reservoir assembly.
    3. Connect the brake master cylinder reservoir assembly connector and air conditioner pressure sensor connector.
  13. INSTALL E.F.I. VACUUM SENSOR ASSEMBLY (MANIFOLD ABSOLUTE PRESSURE SENSOR) 
    1. Install the E.F.I. vacuum sensor assembly (manifold absolute pressure sensor) to the intake air surge tank assembly with the bolt.

      Torque: 7.2 N*m (73 kgf*cm, 64 in.*lbf) 

  14. INSTALL NO. 1 V-BANK COVER BRACKET 

    HINT: 

    Perform this procedure only when replacement of the No. 1 V-bank cover bracket is necessary.

    1. Install the 2 No. 1 V-bank cover brackets to the intake air surge tank assembly.

      Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

  15. INSTALL AIR SURGE TANK TO INTAKE MANIFOLD GASKET 
    1. Install a new air surge tank to intake manifold gasket to the intake air surge tank assembly.
  16. 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. Set the intake air surge tank assembly.
    2. 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) 

    3. Temporarily install the intake air surge tank assembly to the intake manifold with the 5 bolts and 2 nuts.
    4. Temporarily install the No. 2 surge tank stay to the intake air surge tank assembly and camshaft housing sub-assembly with the 2 bolts.
    5. Tighten the 5 bolts and 2 nuts in the order shown in the illustration.
      GTY640737Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut

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

    6. Tighten the 2 bolts in the order shown in the illustration.

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

      Fig 2: Intake Air Surge Tank Tightening Sequence
      GTY661137Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Connect the water hose clamp to the intake air surge tank assembly with the bolt.

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

    8. Engage the 2 wire harness clamps and connect the E.F.I. vacuum sensor assembly (manifold absolute pressure sensor) connector.
  17. CONNECT PURGE VALVE (PURGE VSV) 
    1. Connect the No. 1 fuel vapor feed hose to the intake air surge tank assembly.
    2. Connect the purge valve (purge VSV) to the intake air surge tank assembly with the bolt.

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

  18. CONNECT VENTILATION HOSE 
    1. Connect the ventilation hose to the intake air surge tank assembly and slide the clip to secure it.
  19. INSTALL INJECTOR DRIVER 

    Refer to INSTALLATION [10/2015 - 03/2018] , or refer to INSTALLATION [03/2018 - ]

  20. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to INSTALLATION [10/2015 - ]

  21. INSPECT FOR FUEL LEAK 

    Refer to PROCEDURE - Step 1 [10/2015 - 12/2017] , or refer to PROCEDURE - Step 1 [12/2017 - ]

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