INTAKE MANIFOLD INSTALLATION

PROCEDURE


  1. INSTALL INTAKE MANIFOLD


    1. Install 2 new gaskets to the intake manifold.

    2. Temporarily Install the intake manifold with the 8 bolts and 2 nuts.

    3. A000VYV

      Uniformly tighten the bolts and nuts in the order shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  2. CONNECT PCV HOSE

    A000VASE02
    *1 Upper

    1. Connect the PCV hose to the intake manifold.

      Tech Tips

      Make sure the direction of the hose clamp is as shown in the illustration.

  3. INSTALL PURGE VSV

    A000WQYE01
    *1 Upper
    *2 Rear

    1. Install the purge VSV with the bolt.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    2. Connect the 2 purge line hoses.

      Tech Tips

      Make sure the direction of the hose clamp is as shown in the illustration.

    3. Connect the purge VSV connector.

  4. INSTALL WATER BY-PASS PIPE HOSE

    A000ZYME02
    *1 Upper

    1. Install the water by-pass pipe hose with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Connect the 4 water hoses.

      Tech Tips

      Make sure the direction of the hose clamp is as shown in the illustration.

  5. INSTALL NO. 3 ENGINE COVER SUB-ASSEMBLY


    1. A000Y6B

      Install the No. 3 cover sub-assembly with the 2 clips.

  6. INSTALL ENGINE MOTOR CABLE CLAMP BRACKET (for LHD)


    1. A000ZON

      Install the engine motor cable clamp bracket with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Connect the wire harness clamp to the motor cable clamp bracket.

  7. INSTALL FLEXIBLE HOSE BRACKET SUB-ASSEMBLY (for LHD)


    1. A000WEW

      Install the flexible hose bracket sub-assembly with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    2. Connect the flexible hose to the bracket.

  8. INSTALL NO. 2 ENGINE MOTOR CABLE CLAMP BRACKET (for RHD)


    1. A000Y2W

      Install the No. 2 engine motor cable bracket with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Attach the 2 wire harness clamps to the bracket.

  9. INSTALL NO. 1 ENGINE MOTOR CABLE CLAMP BRACKET (for RHD)


    1. Install the No. 1 engine motor cable clamp bracket with the bolt to the No. 2 engine motor cable bracket.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  10. CONNECT GENERATOR CABLE (for RHD)


    1. A000TPNE03
      *1 Generator Cable
      *2 Motor Cable

      Connect the generator cable with the 2 clamps.

  11. CONNECT MOTOR CABLE (for RHD)


    1. Connect the motor cable with the clamp.

  12. INSTALL INJECTOR DRIVER


    1. Install the No. 1 engine cover to the intake manifold.

    2. A000TGEE05
      *a Nut

      Install the injector driver with the 2 bolts and 2 nuts.

    3. Uniformly tighten the bolts and nuts in the order shown in the illustration.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    4. A000YZTE01
      *1 Lock Lever

      Connect the 4 wire harness connectors to the injector driver. Then move the lock lever as shown in the illustration to lock the connectors.

    5. Connect the 3 wire harness claws to the bracket.

  13. CONNECT ENGINE WIRE HARNESS (for LHD)


    1. Connect the engine wire harness protector to the intake manifold with the 4 nuts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Connect the 3 wire harness brackets with the 3 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    3. Connect the 4 ground cables with the 4 bolts.

      Torque:
      for timing chain cover
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for engine room RH side
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

    4. Connect the 3 engine wire harness clamps labeled B.

    5. Attach the 4 engine wire harness clamps labeled A.

    6. Connect the engine wire harness connectors.

      Tech Tips

      Connect the 4 wire harness connectors to the injector driver. Then move the lock lever as shown in the illustration to lock the connectors.

      A000UK8E03

  14. CONNECT ENGINE WIRE HARNESS (for RHD)


    1. Connect the engine wire harness protector to the intake manifold with the 4 nuts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Connect the 4 wire harness brackets with the 4 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    3. Connect the 4 ground cables with the 4 bolts.

      Torque:
      for timing chain cover
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for engine room RH side
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

    4. Connect the 3 engine wire harness clamps labeled B.

    5. Attach the 4 engine wire harness clamps labeled A.

    6. Connect the engine wire harness connectors.

      Tech Tips

      Connect the 4 wire harness connectors to the injector driver. Then move the lock lever as shown in the illustration to lock the connectors.

      A000W0KE02

  15. CONNECT ECM CONNECTOR


    1. A000XFS

      Connect the engine wire harness to the ECM box and connect the 4 ECM connectors.

  16. CONNECT NO. 2 CONNECTOR HOLDER


    1. A000V4WE04
      *1 Holder
      *2 Clamp A

      Attach the No. 2 connector holder.

    2. Attach the wire harness clamp A to the ECM box.

    3. Connect the 3 connectors.

  17. CONNECT HYBRID VEHICLE CONTROL ECU CONNECTOR


    1. A000ZVL

      Connect the connector to the hybrid vehicle control ECU.

  18. INSTALL OUTLET ENGINE ROOM ECM DUCT

    Click here

  19. INSTALL ENGINE ROOM ECU COVER

    Click here

  20. INSTALL NO. 6 COVER SUB-ASSEMBLY (for LHD)


    1. A000UT1E06
      *1 Engine Cover Sub-Assembly LH
      *2 No. 6 Cover Sub-Assembly

      Install the No. 6 cover sub-assembly.

  21. INSTALL ENGINE COVER SUB-ASSEMBLY LH (for LHD)


    1. Install the engine cover sub-assembly LH with the 4 nuts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  22. INSTALL NO. 5 COVER SUB-ASSEMBLY (for RHD)


    1. A000W9HE03
      *1 Engine Cover Sub-Assembly RH
      *2 No. 5 Cover Sub-Assembly

      Install the No. 5 cover sub-assembly.

  23. INSTALL ENGINE COVER SUB-ASSEMBLY RH (for RHD)


    1. Install the engine cover sub-assembly RH with the 4 nuts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  24. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE (for RHD)

    Click here

  25. INSTALL ENGINE OIL LEVEL DIPSTICK (for RHD)

  26. INSTALL SKID CONTROL ECU BRACKET (for LHD)

    Click here

  27. INSTALL SKID CONTROL ECU BRACKET (for RHD)

    Click here

  28. INSTALL AIR CLEANER ASSEMBLY RH

    Click here

  29. INSTALL AIR CLEANER ASSEMBLY LH

    Click here

  30. INSTALL THROTTLE BODY ASSEMBLY

    Click here

  31. INSTALL SERVICE PLUG GRIP

    Click here

  32. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Note

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

  33. INSTALL DECK TRIM SIDE BOARD LH (w/o Spare Tire)

    Click here

  34. INSTALL LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY

    Click here

  35. INSTALL ENGINE ROOM SIDE COVER LH

    Click here

  36. INSTALL ENGINE ROOM SIDE COVER RH

    Click here