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Installation [09/2015 - ]: 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) 

      GTY627992Courtesy 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 each cylinder head sub-assembly.
      NOTE:
      • Align the port holes of the No. 1 intake manifold to head gaskets and cylinder head sub-assembly.
      • 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 with the 4 bolts and 4 nuts.
    2. Tighten the 4 bolts and 4 nuts in the order shown in the illustration.
      Fig 1: Intake Manifold Tightening Sequence
      GTY657526Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut

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

  4. INSTALL INJECTOR VIBRATION INSULATOR 

    Refer to PROCEDURE - Step 2

  5. INSTALL NO. 1 DELIVERY PIPE SPACER 

    Refer to PROCEDURE - Step 3

  6. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  7. CONNECT FUEL TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  8. 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) 

      GTY627991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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) 

    3. Engage the wire harness clamp to the wire harness clamp bracket.
    4. 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) 

      GTY633625Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
  9. 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) 

  10. 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.
  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. Connect the vacuum hose sub-assembly to the intake air surge tank assembly.
    2. Temporarily install the intake air surge tank assembly to the intake manifold with the 5 bolts and 2 nuts.
    3. Temporarily install the No. 2 surge tank stay to the intake manifold and camshaft housing RH with the 2 bolts.
    4. Tighten the 5 bolts and 2 nuts in the order shown in the illustration.

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

      Fig 2: Intake Air Surge Tank Assembly Tightening Sequence
      GTY677726Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    5. Tighten the 2 bolts in the order shown in the illustration.

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

      GTY625576Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Engage the clamp to connect the No. 2 air tube to the intake air surge tank assembly.
      GTY644482Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Vacuum Hose Sub-assembly
      *2 No. 2 Air Tube
    7. Engage the 2 clamps to connect the vacuum hose sub-assembly to the intake air surge tank assembly.
    8. Engage the 5 clamps to connect the vacuum hose sub-assembly to the intake air surge tank assembly.
      GTY630615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Vacuum Switching Valve (for ACIS) Connector
      *b Wire Harness Clamp
      *c Vacuum Hose Sub-assembly
    9. Engage the wire harness clamp to the intake air surge tank assembly.
    10. Connect the vacuum switching valve (for ACIS) connector.
  12. CONNECT PURGE VALVE (PURGE VSV) 
    1. 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) 

    2. Connect the No. 1 fuel vapor feed hose to the intake air surge tank assembly.
  13. CONNECT VENTILATION HOSE 
    1. Connect the ventilation hose to the intake air surge tank assembly and slide the clip to secure it.
  14. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to INSTALLATION [09/2015 - ]

  15. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Refer to INITIALIZATION [09/2015 - 08/2016] , or refer to INITIALIZATION [08/2016 - 12/2017] , or refer to INITIALIZATION [12/2017 - 08/2019] , or refer to INITIALIZATION [08/2019 - ]

  16. INSPECT FOR FUEL LEAK 

    Refer to PROCEDURE - Step 1 [09/2015 - 12/2017] , or refer to PROCEDURE - Step 1 [12/2017 - ]

  17. INSTALL V-BANK COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 40 [09/2015 - 08/2016] , or refer to PROCEDURE - Step 40 [08/2016 - 12/2017] , or refer to PROCEDURE - Step 40 [12/2017 - 08/2019] , or refer to PROCEDURE - Step 40 [08/2019 - ]

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