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Installation [02/2024 - ]: Procedure

  1. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY 
    1. GTY1188578Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion - -
      1. Install a new throttle body gasket to the intake manifold with the protrusion of the throttle body gasket oriented as shown in the illustration.
      2. Install the throttle body with motor assembly to the intake manifold.
        NOTE:

        If the throttle body with motor assembly has been struck or dropped, replace it.

  2. INSTALL NO. 2 AIR TUBE 
    1. GTY1191499Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion - -
      1. Install a new throttle body gasket to the No. 2 air tube with the protrusion of the throttle body gasket oriented as shown in the illustration.
      2. Install the No. 2 air tube to the throttle body with motor assembly and intake manifold with the 4 bolts.

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

  3. INSTALL AIR TUBE SUPPORT 

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

  4. INSTALL INTAKE MANIFOLD STAY 

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

  5. INSTALL NO. 1 TURBO PRESSURE SENSOR 
    NOTE:

    If the No. 1 turbo pressure sensor has been struck or dropped, replace it.

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

  6. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET 
  7. INSTALL INTAKE MANIFOLD 
    1. Fig 1: Intake Manifold Tightening Sequence
      GTY1220617Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt A Bolt B
      Nut - -
      1. Temporarily install the intake manifold and fuel delivery guard with 4 bolts and 2 nuts.
      2. Tighten the 4 bolts and 2 nuts in the order shown in the illustration.

        for bolt A 

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

        for bolt B 

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

      3. Install the air tube support to the engine assembly with the bolt.

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

  8. CONNECT NO. 5 WATER BY-PASS HOSE 
    1. GTY1222348Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 45° (Claw of Clip Location) *b Paint Mark
      *c Uppre Side of Vehicle *d Front Side of Vehicle
      1. Install the No. 5 water by-pass hose to the throttle body with motor assembly and slide the clip to secure it.
        NOTE:

        Make sure to position the clip as shown in the illustration.

  9. CONNECT NO. 4 WATER BY-PASS HOSE 
    1. GTY1226346Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 45° (Claw of Clip Location) *b Paint Mark
      *c Right Side of Vehicle *d Rear Side of Vehicle
      1. Install the No. 4 water by-pass hose to the throttle body with motor assembly and slide the clip to secure it.
        NOTE:

        Make sure to position the clip as shown in the illustration.

  10. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE 
    1. GTY1191790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Apply a light coat of engine oil to a new O-ring.
      2. Install the O-ring to the engine oil level dipstick guide.
      3. Install the engine oil level dipstick guide to the intake manifold with the bolt.

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

      4. Install the engine oil level dipstick.
  11. INSTALL NO. 1 WATER HOSE CLAMP BRACKET 

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

  12. CONNECT WATER BY-PASS HOSE ASSEMBLY WITH NO. 2 WATER BY-PASS HOSE 
  13. CONNECT FUEL TUBE SUB-ASSEMBLY 
  14. INSTALL VACUUM SWITCHING VALVE BRACKET 

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

  15. INSTALL NO. 1 FUEL VAPOR FEED HOSE 
    1. GTY1224163Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 45° (Claw of Clip Location) *b Uppre Side of Vehicle
      *c Front Side of Vehicle - -
      1. Install the No. 1 fuel vapor feed hose to the intake manifold and slide the clip to secure it.
        NOTE:

        Make sure to position the clip as shown in the illustration.

  16. INSTALL PURGE VSV (DUTY VACUUM SWITCHING VALVE) 
    Refer to PROCEDURE - Step 1
  17. CONNECT ENGINE WIRE 
  18. INSTALL NO. 2 AIR HOSE 
    1. GTY1184443Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Retainer - -
      1. Connect the No. 2 air hose to the intercooler assembly and lock the 2 retainers as shown in the illustration.
        NOTE:

        Securely insert the retainer so that the 4 locks are engaged. Then, pull and check that the locks are engaged and that the hose cannot be pulled out.

        HINT: 

        • Install so that the protrusion on the intercooler assembly and the stoppers are aligned.
        • Make sure that the retainer end contacts the stopper as shown in the illustration.
        GTY1224142Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Correct
        *b Incorrect
        *c Retainer End
        *d Stopper
        *e Protrusion
  19. CONNECT RADIATOR HOSE SUB-ASSEMBLY 
    1. GTY1227126Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark *b Upper Side of Vehicle
      *c Right Side of Vehicle *d Front Side of Vehicle
      *e 120° - -
      1. Connect the radiator hose sub-assembly to the intercooler assembly, engine assembly and slide the hose clamp to secure the hose.
        NOTE:

        Make sure to position the clip as shown in the illustration.

      2. Install the radiator hose sub-assembly to the intake manifold with the 2 bolts.

        Torque: 5.0 N.m (51 kgf/cm, 44 in.lbf) 

  20. ADD ENGINE COOLANT 

    Refer to PROCEDURE - Step 4

  21. INSPECT FOR COOLANT LEAK 

    Refer to PROCEDURE - Step 1

  22. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  23. INITIALIZATION AFTER RECONNECTING BATTERY TERMINAL 

    HINT: 

    When disconnecting and reconnecting the battery, there is an automatic learning function that completes learning when the respective system is used.

    Refer to AUTOMATIC LEARNING CHART [02/2024 - ]

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