INTAKE MANIFOLD INSTALLATION

INSTALL EGR VALVE ASSEMBLY
1. Install a new gasket to the cylinder head.
2. Insert the EGR valve into the stud bolt, rotate the EGR valve to avoid contact with the delivery pipe, and temporarily install the EGR valve.
3. Connect the water by-pass hose.
4. Connect the EGR valve connector.
INSTALL NO. 1 INTAKE MANIFOLD INSULATOR
1. Temporarily install the intake manifold insulator with a new gasket, the 2 bolts and the nut.
INSTALL DUTY VACUUM SWITCHING VALVE
1. Connect the fuel vapor feed hose to the intake manifold.
2. Install the duty vacuum switching valve with the bolt.
  
  Torque:
  
  8.8 N*m { 90 kgf*cm, 78 in.*lbf }
INSTALL E.F.I. VACUUM SENSOR ASSEMBLY
1. Install the E.F.I. vacuum sensor assembly with the screw.
INSTALL INTAKE MANIFOLD
1. Install the stud bolt on the intake manifold.
2. Install a new gasket on the intake manifold.
3. Temporarily install the intake manifold with the 2 bolts and 2 nuts.
4. Tighten the 4 bolts and 3 nuts in the sequence shown in the illustration.
  
  Torque:
  
  30 N*m { 306 kgf*cm, 22 ft.*lbf }
5. Connect the union to check valve hose with the hose clamp.
6. Connect the vacuum hose.
7. Connect the ventilation hose with the hose clamp.
8. Tighten the 2 bolts.
  
  Torque:
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf }
9. Engage the 4 wire harness clamps and install the wire harness to the intake manifold.
10. Connect the vacuum sensor connector.
11. Install the 2 water by-pass hoses on the intake manifold.
12. Connect the fuel vapor feed hose with the hose clamp.
13. Connect the vacuum switching valve connector
INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY

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CONNECT OUTLET HEATER WATER HOSE (for LHD)
1. Install the heater water outlet hose onto the heater unit.
  
  Tech Tips
  
  Perform the installation with the hose clip and mark at the correct angle.
CONNECT INLET HEATER WATER HOSE (for LHD)
1. Install the heater water inlet hose onto the heater unit.
  
  Tech Tips
  
  Perform the installation with the hose clip and mark at the correct angle.
CONNECT FUEL TUBE SUB-ASSEMBLY (for LHD)
1. Push the tube connector into the pipe until the tube connector makes a "click" sound.
  Note
  - Check whether there is any damage or foreign matter on the connected part of the fuel pipe.
  - Check that the fuel tube connector and the pipe are securely connected by pulling on them after connecting.
INSTALL EFI FUEL PIPE CLAMP (for LHD)
1. Install the No. 1 fuel pipe clamp.
INSTALL BATTERY (for LHD)
1. Install the battery onto the vehicle.
2. Install the battery clamp with the 2 nuts.
  
  Torque:
  
  3.5 N*m { 36 kgf*cm, 35 in.*lbf }
3. Connect the cable to the battery terminal.
  
  Torque:
  
  5.0 N*m { 55 kgf*cm, 43 in.*lbf }
INSTALL WINDSHIELD WIPER MOTOR AND LINK

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ADD ENGINE COOLANT

Tighten the radiator drain cock plug.
Remove the water filler cap sub-assembly.

Slowly fill the radiator with TOYOTA Super Long Life Coolant (SLLC).

Standard Capacity

Item	Capacity
for Manual Transaxle	4.3 liters (4.5 US qts, 3.8 Imp. qts)
for CVT	4.5 liters (4.8 US qts, 4.0 Imp. qts)

Note

Never use water as a substitute 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).

Squeeze the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.

If the coolant level is low, add coolant.
Text in Illustration

*a FULL Line

Fill the radiator reserve tank with coolant to the FULL level.
Install the water filler cap sub-assembly.
Start the engine and warm it up.
Bleed air from the cooling system.
Note
- Before starting the engine, turn the A/C switch off.
- Adjust the air conditioning temperature setting to MAX (HOT).
- Adjust the air conditioning blower setting to LO.
1. Warm up the engine until the thermostat opens. While the thermostat is open, allow the coolant to circulate for several minutes.
  
  Tech Tips
  
  Thermostat opening timing can be determined by squeezing the inlet radiator hose, and sensing vibrations when the engine coolant starts to flow inside the hose.
  CAUTION:
  When squeezing the radiator hoses:
  - Wear protective gloves.
  - Be careful as the radiator hoses are hot.
  - Keep your hands away from the radiator fan.
Stop the engine, and wait until the engine coolant cools down.
Remove the water filler cap sub-assembly and check the coolant level.

If the coolant level is below the LOW line, repeat all of the procedures above.
Text in Illustration

*a FULL Line

*b LOW Line

When the coolant level stops going down, check that the coolant level is between the FULL and LOW lines.

If the coolant level is low, add coolant to the reservoir tank FULL line.

INSPECT FOR ENGINE COOLANT LEAK

CAUTION:

To avoid the danger of being burned, do not remove the water filler cap sub-assembly while the engine and radiator assembly are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator assembly.
1. Text in Illustration
  
  *1 Radiator Cap Tester
  
  Fill the radiator assembly with engine coolant, and attach a radiator cap tester.
2. Pump the tester to 118 kPa (1.2 kgf/cm², 17.1 psi), and then check that the pressure does not drop.
  
  If the pressure drops, check the hoses, radiator assembly and water pump assembly for leaks. If there are no signs or traces of external engine coolant leaks, check the heater core, cylinder block and head.

Text in Illustration
*a	FULL Line
*b	LOW Line