Installation [11/2015 -]: Procedure

HINT: 

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

1. Using an E6 "TORX" socket wrench, install the 2 stud bolts to the intake manifold.

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new No. 1 intake manifold to head gasket to the intake manifold.

1. Temporarily install the intake manifold to the cylinder head sub-assembly with the 3 bolts and 2 nuts.
2. Tighten the 3 bolts and 2 nuts in several steps.

   Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) 

   Fig 1: Intake Manifold Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   	Bolt
   	Nut

1. Engage the 2 hose clamps to connect the No. 2 water by-pass hose to the intake manifold.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Water By-Pass Hose
   *2	No. 2 Water By-pass Hose

2. Engage the 2 hose clamps to connect the water by-pass hose to the intake manifold.

1. Engage the 2 hose clamps to connect the No. 2 fuel vapor feed hose to the intake manifold.
2. Connect the No. 2 fuel vapor feed hose to the intake manifold.

1. Connect the No. 8 water by-pass hose to the No. 3 water by-pass pipe and slide the clip to secure it.
2. Engage the 2 hose clamps.

1. Connect the engine cover bracket to the intake manifold with the bolt.

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

1. Engage the clamp and connect the engine wire with the bolt.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

2. Connect the 4 fuel injector assembly connectors and purge valve (purge VSV) connectors.
3. Connect the wire harness bracket with the bolt.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

4. Connect the engine water pump assembly connector.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

5. Engage the 2 clamps.

1. Connect the ventilation hose to the intake manifold and slide the clip to secure it.

1. Install the E.F.I. vacuum sensor assembly (manifold absolute pressure sensor) to the intake manifold with the bolt.

   Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 

2. Connect the vacuum hose to the intake manifold.
3. Connect the E.F.I. vacuum sensor assembly (manifold absolute pressure sensor) connector.

1. Install a new EGR pipe gasket to the EGR valve assembly.
   NOTE:

   Make sure that the claws of the EGR valve gasket are toward the EGR valve assembly side.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Claw

2. Install a new inlet EGR gasket to the intake manifold.

   HINT: 

   Align the protrusion of the inlet EGR gasket with the groove of the intake manifold.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Groove
   *b	Protrusion

3. Install the EGR pipe assembly to the intake manifold and EGR valve assembly with the 4 bolts.

   Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) 

1. Install the inlet No. 1 air cleaner to the intake manifold with the 2 bolts.

   Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 

1. Engage the wire harness clamp and install the air cleaner bracket to the cylinder block sub-assembly and air conditioning wire with the bolt (A) and 2 bolts (B).

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Bolt (A)
   *b	Bolt (B)

   Bolt (A) 

   Torque: 12.5 N*m (127 kgf*cm, 9 ft.*lbf) 

   Bolt (B) 

   Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 

1. Install the air cleaner case sub-assembly to the air cleaner bracket with the 2 bolts.

   Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 

1. Install the air cleaner filter element sub-assembly to the air cleaner case sub-assembly.

1. Temporarily install the inlet No. 2 air cleaner to the inlet No. 1 air cleaner and upper radiator support sub-assembly with the 2 bolts.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Groove
   *b	Protrusion

   HINT: 

   Align the protrusion of the inlet No. 1 air cleaner with the groove of the inlet No. 2 air cleaner.

2. Tighten the 2 bolts.

   Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 

3. Tighten the hose clamp.

   Torque: 2.0 N*m (20 kgf*cm, 18 in.*lbf) 

Refer to PROCEDURE - Step 2 [11/2015 - 12/2018] , or refer to PROCEDURE - Step 2 [12/2018 -]

Refer to INSTALLATION [11/2015 -]