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Installation [08/2023 - ]: Procedure

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  1. INSTALL VACUUM HOSE 
  2. INSTALL NO. 1 ENGINE COVER 
  3. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET 
  4. INSTALL INTAKE MANIFOLD 
    1. w/ Stud Bolt:
      GTY1133786Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Temporarily install the intake manifold to the cylinder head sub-assembly.
      2. Using an E8 "TORX" socket wrench, install the 2 stud bolts.

        Torque: 6.5 N.m (66 kgf/cm, 58 in.lbf) 

      3. Temporarily install the 3 bolts and 2 nuts.
      4. Tighten the 3 bolts and 2 nuts in the order shown in the illustration.

        Torque: 24 N.m (245 kgf/cm, 18 ft.lbf) 

    2. w/o Stud Bolt:
      GTY1133053Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Temporarily install the intake manifold to the cylinder head sub-assembly with the 5 bolts.
      2. Tighten the 5 bolts in the order shown in the illustration.

        Torque: 24 N.m (245 kgf/cm, 18 ft.lbf) 

  5. INSTALL NO. 2 FUEL VAPOR FEED HOSE 
  6. INSTALL NO. 2 WATER BY-PASS PIPE 
    1. GTY1130837Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Temporarily install the No. 2 water by-pass pipe to the cylinder block sub-assembly with the bolt (B).
      2. Using an 8 mm socket wrench, temporarily install the No. 2 water by-pass pipe to the intake manifold with the 2 bolts (A).
      3. Tighten the bolt (B).

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

      4. Using an 8 mm socket wrench, tighten the 2 bolts (A).

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

      5. Engage the wire harness clamp.
  7. CONNECT NO. 3 WATER BY-PASS PIPE 
    1. GTY1129772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an 8 mm socket wrench, connect the No. 3 water by-pass pipe to the intake manifold with the bolt.

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

  8. CONNECT NO. 5 WATER BY-PASS HOSE 
  9. INSTALL EGR INLET GASKET 
  10. INSTALL EGR VALVE ADAPTER GASKET 
  11. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 12
  12. CONNECT ENGINE WIRE 

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

  13. CONNECT NO. 2 FUEL VAPOR FEED HOSE 
  14. CONNECT NO. 1 FUEL VAPOR FEED HOSE 
  15. INSTALL PURGE VALVE (PURGE VSV) 

    Refer to INSTALLATION [10/2022 - ]

  16. INSTALL E.F.I. VACUUM SENSOR ASSEMBLY (MANIFOLD ABSOLUTE PRESSURE SENSOR) 

    Refer to INSTALLATION [10/2022 - ]

  17. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to INSTALLATION [08/2023 - ]

  18. INSTALL SUCTION HOSE SUB-ASSEMBLY (for PHEV Model) 
    1. GTY1205110Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the vinyl tape wrapped around the connection of each part and suction hose sub-assembly, and sufficiently apply compressor oil to 2 new O-rings and the fitting surface of each part.

        Compressor Oil

        ND-OIL 11 or equivalent

      2. Install the 2 O-rings to the suction hose sub-assembly.
        NOTE:

        Keep the O-ring and O-ring fitting surface free from foreign matter.

      3. Connect the suction hose sub-assembly with the 2 bolts.

        Torque: 9.8 N.m (100 kgf/cm, 87 in.lbf) 

  19. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT (for PHEV Model) 

    Refer to PROCEDURE - Step 3

  20. WARM UP COMPRESSOR (for PHEV Model) 

    Refer to PROCEDURE - Step 4

  21. INSPECT FOR REFRIGERANT LEAK (for PHEV Model) 

    Refer to PROCEDURE - Step 6

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