INTAKE MANIFOLD INSTALLATION


  1. INSTALL INTAKE MANIFOLD


    1. Set 2 new gaskets on each cylinder head sub-assembly.

      Note


      • Align the port holes of the gaskets and cylinder head sub-assembly.

      • Make sure that the gaskets are installed in the correct direction.

    2. Set the intake manifold on the cylinder head sub-assembly.

    3. Install and tighten the 6 bolts and 4 nuts uniformly in several steps.

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

  2. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. Install 6 new injector vibration insulators to the intake manifold.

    2. Place the fuel delivery pipe sub-assembly with the 6 fuel injector assemblies in position on the intake manifold.

      Note

      Be careful not to drop the fuel injector assemblies when installing the fuel delivery pipe sub-assembly.

    3. A01G8VQ

      Temporarily install the 5 bolts which are used to hold the fuel delivery pipe sub-assembly to the intake manifold.

      Note

      After installing the fuel injector assemblies, check that they turn smoothly. If not, reinstall them with new O-rings.

    4. Tighten the 5 bolts which are used to hold the fuel delivery pipe sub-assembly to the intake manifold.

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

    5. Connect the 6 fuel injector connectors.

  3. CONNECT FUEL TUBE SUB-ASSEMBLY


    1. A01G8I8E06
      Text in Illustration
      *1 No. 2 Fuel Pipe Clamp
      *2 Retainer
      *3 Fuel Tube Connector
      *4 O-ring
      *5 Fuel Pipe
      A01G8AH Push

      Push in the fuel tube connector onto the fuel pipe until the fuel tube connector makes a "click" sound.

      Note


      • Before connecting the fuel tube connector and fuel pipe, check that there is no damage or foreign matter on the connecting part of the fuel pipe.

      • After connecting the fuel tube connector and fuel pipe, check that they are securely connected by trying to pull them apart.

    2. Install the No. 2 fuel pipe clamp.

  4. INSTALL NO. 2 ENGINE MOUNTING STAY RH (for Intake Manifold Side)


    1. Install the No. 2 engine mounting stay RH with the bolt.

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

  5. INSTALL NO. 2 ENGINE MOUNTING STAY RH (for Engine Mounting Stay Side)


    1. Install the No. 2 engine mounting stay RH with the bolt.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

    2. Tighten the 2 nuts.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

  6. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

    Note

    Do not apply oil to the bolts listed below:

    Oil Application Prohibited Bolt
    Bolt for Intake Air Surge Tank Assembly and Intake Manifold
    Bolt for No. 1 Surge Tank Stay and Intake Air Surge Tank Assembly
    Bolt for Throttle Body Bracket and Intake Air Surge Tank Assembly

    1. Install 3 new gaskets to the intake air surge tank assembly.

    2. Temporarily install the intake air surge tank assembly with the 4 bolts and 2 nuts.

    3. A01G57KE03

      Using a 5 mm hexagon socket wrench, in several steps, uniformly tighten the 4 bolts and 2 nuts in the order shown in the illustration.

      Torque:
      Bolt
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
      Nut
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

    4. Install the No. 1 surge tank stay to the intake air surge tank assembly with the bolt.

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

    5. Install the throttle body bracket to the intake air surge tank assembly with the bolt.

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

    6. Install the vacuum hose clamp to the throttle body bracket with the bolt.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

      Tech Tips

      Install the vacuum hose clamp so that its tab is in contact with the No. 1 surge tank stay.

    7. Connect the intake air control valve assembly connector.

    8. Connect the fuel vapor feed hose to the intake air surge tank assembly.

    9. Connect the 2 water by-pass hoses to the throttle body assembly and slide the 2 clips to secure them.

    10. Connect the throttle body assembly connector.

    11. Engage the wire harness clamp.

    12. for LHD:


      1. Engage the hose clamp.

      2. Connect the union to check valve hose to the intake air surge tank assembly and slide the clip to secure it.

    13. for RHD:


      1. Connect the union to check valve hose to the intake air surge tank assembly and slide the clip to secure it.

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

  7. INSTALL AIR CLEANER CAP SUB-ASSEMBLY


    1. Connect the air cleaner cap sub-assembly to the throttle with motor body assembly with the hose clamp.

    2. Install the air cleaner cap sub-assembly to the air cleaner case with the 2 clamps.

    3. Connect the 3 hoses.

    4. Connect the ventilation hose.

    5. Connect the mass air flow meter connector and wire harness clamp.

  8. INSTALL FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY (for LHD)


    1. Install the front outer cowl top panel sub-assembly with the 10 bolts.

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

    2. Engage the 2 clamps to install the wire harness to the front outer cowl top panel sub-assembly.

    3. A01G885E01

      Connect the connector to install the wire harness to the front outer cowl top panel sub-assembly.

    4. Engage the 2 clamps (B).

    5. w/ Wiper Deicer System:

      Engage the clamp (A).

  9. INSTALL FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)


    1. Install the front outer cowl top panel sub-assembly with the 10 bolts.

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

    2. Engage the 2 clamps to install the wire harness to the front outer cowl top panel sub-assembly.

  10. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  12. ADD ENGINE COOLANT


    1. Tighten the radiator drain cock plug by hand.

    2. Tighten the cylinder block drain cock plug. (for Bank 1)

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

    3. Tighten the cylinder block drain cock plug. (for Bank 2, w/ Cylinder Block Drain Cock Plug)

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

    4. Loosen the air drain cock plug on the water inlet housing.

    5. Add engine coolant to the radiator inlet opening until engine coolant overflows from the air drain cock hole. Then tighten the air drain cock plug to the water inlet housing.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }
    6. A01G5B0E01
      Text in Illustration
      *a Code Mark

      Check the code mark on the fan shroud.

    7. Slowly fill the radiator assembly with engine coolant.

      Specified Capacity:
      Code Mark I and V 9.2 liters (9.7 US qts, 8.1 Imp. qts)
      Code Mark W 9.4 liters (9.9 US qts, 8.3 Imp. qts)

      Note

      Do not substitute plain water for engine coolant.

      Tech Tips

      TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology is a combination of low phosphates and organic acids).

    8. Slowly pour engine coolant into the radiator reserve tank assembly until it reaches the full line.

    9. Squeeze the No. 1 radiator hose and No. 2 radiator hose several times by hand, and then check the level of the engine coolant.

      If the engine coolant level is low, add engine coolant.

    10. Install the radiator cap sub-assembly and reserve tank cap.

    11. Bleed air from the cooling system.

      Note


      • Before starting the engine, turn the A/C switch off.

      • Adjust the heater control to the maximum hot setting.

      • Adjust the blower speed to the low setting.


      1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the engine coolant for several minutes.

        Tech Tips

        The thermostat open timing can be confirmed by squeezing the No. 2 radiator hose by hand, and sensing vibrations when the engine coolant starts to flow inside the No. 2 radiator hose.

      2. Maintain the engine speed at 2500 to 3000 rpm.

      3. Squeeze the No. 1 radiator hose and No. 2 radiator hose several times by hand to bleed air.

        CAUTION:

        When squeezing the No. 1 radiator hose and No. 2 radiator hose:


        • Wear protective gloves.

        • Be careful as the No. 1 radiator hose and No. 2 radiator hose are hot.

        • Keep your hands away from the fan and No. 2 fan.

        Note


        • If the coolant temperature gauge indicates an excessive temperature, turn off the engine and let it cool.

        • Make sure that the radiator reserve tank assembly still has some engine coolant in it.

        • If the radiator reserve tank assembly does not have enough engine coolant, the engine may overheat or be seriously damaged.

        • If the radiator reserve tank assembly does not have enough engine coolant, perform the following: 1) stop the engine, 2) wait until the engine coolant has cooled down, and 3) add engine coolant until the radiator reserve tank assembly is filled to the full line.

    12. Stop the engine, and wait until the engine coolant cools down.

    13. Add engine coolant to the full line on the radiator reserve tank assembly.

  13. INSPECT FOR COOLANT LEAK

    CAUTION:

    Do not remove the radiator cap sub-assembly while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    Note

    Before performing each inspection, turn the A/C switch OFF.


    1. A01G6OC

      Fill the radiator with engine coolant and attach a radiator cap tester.

    2. Warm up the engine.

    3. Using a radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf*cm, 17 psi), and check that the pressure does not drop.

      If the pressure drops, check the hoses, radiator assembly and engine water pump assembly for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.

  14. INSPECT FOR FUEL LEAK


    1. Check fuel pump operation.


      1. Connect the GTS to the DLC3.

      2. Turn the engine switch on (IG) and turn the GTS on.

        Note

        Do not start the engine.

      3. Enter the following menus: Powertrain / Engine / Active Test / Control the Fuel Pump / Speed.

      4. Check for pressure in the fuel tube sub-assembly from the fuel pipe. Check that sounds of fuel flowing from the fuel tank can be heard. If no sounds can be heard, check the integration relay, fuel pump, ECM and wiring connectors.

    2. Inspect for fuel leaks.


      1. Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs. If there is a fuel leak, repair or replace parts as necessary.

    3. Turn the engine switch off.

    4. Disconnect the GTS from the DLC3.

  15. INSTALL V-BANK COVER SUB-ASSEMBLY


    1. Fit the 3 retainers and install the V-bank cover sub-assembly.