Installation [12/2023 - ]: Procedure

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   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.
      • Face the identification protrusion (*a) towards the right side of the vehicle on the right bank side.
      • Face the identification protrusion (*b) towards the left side of the vehicle on the left bank side.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      HINT: 

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

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

2. Fig 1: Intake Manifold Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Bolt

   Nut

   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) 

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Claw

   -

   -

   1. Install a new No. 2 EGR pipe gasket to the No. 2 EGR pipe.
      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.

1. Fig 2: No. 2 EGR Pipe Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   	Bolt		Nut
   	Stud bolt	-	-

   1. Set the No. 2 EGR pipe.
   2. Using an E6 "TORX" socket wrench, install the stud bolt to the intake manifold.

      HINT: 

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

      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) 

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

1. Fig 3: No. 2 Engine Mounting Stay RH Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Engine Wire	*2	Wire Harness Clamp Bracket
   	Bolt		Nut
   	Connector	-	-

   1. Temporarily install the No. 2 engine mounting stay RH to the engine mounting insulator sub-assembly RH with the bolt and 2 nuts.
   2. Tighten the bolt and 2 nuts in the order shown in the illustration.

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

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

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

   4. Connect the EGR valve assembly connector.
   5. Connect the fuel tube sub-assembly connector.
   6. Engage the wire harness clamp to the wire harness clamp bracket.

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

HINT: 

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

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

NOTE: Do not apply oil to the bolts and nuts. Do not apply oil to the intake air surge tank assembly and intake manifold.

1. Fig 4: Intake Air Surge Tank Assembly Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   	Bolt		Nut
   	Stud bolt		Install in this direction

   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.

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

NOTE: Do not apply oil to the bolts and nuts.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Torque Wrench Fulcrum Length

   -

   -

   1. Using SST, install the No. 2 surge tank stay to the camshaft housing sub-assembly with the bolt.
      • SST: 09729-00120 

      Specified Tightening Torque 

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

      HINT: 

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Refer to PRECAUTION [09/2023 - ]

      • When using SST (fulcrum length of 200 mm (7.87 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

        9.4 N*m (96 kgf*cm, 83 in.*lbf)

   2. Install the No. 2 surge tank stay to the intake air surge tank assembly with the bolt.

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

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

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	5 to 11 mm (0.197 to 0.433 in.)	*b	Paint Mark (Upper Side of Vehicle)
   *c	Right Side of Vehicle	-	-

   1. Connect the ventilation hose to the intake air surge tank assembly and slide the clip to secure it.
      NOTE:

      • Make sure that the claws of the clip are within the location shown in the illustration.
      • Make sure to align the paint mark of the vetilation hose within the location shown in the illustration.

Refer to INSTALLATION [12/2023 - ]

Refer to PROCEDURE - Step 1