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Intake Manifold: Installation

NOTE: While the battery is connected, even if the power switch is OFF, the brake control system activates when the brake pedal is depressed or the door courtesy switch turns on. Therefore during servicing of the brake system components, do not operate the brake pedal or open/ close the doors while the battery is connected.
  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. Uniformly tighten the bolts and nuts in the order shown in the illustration.

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

      Fig 1: Identifying Intake Manifold Tightening Sequence
      G05773226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. CONNECT PCV HOSE 

    HINT.

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

    Fig 2: Identifying PCV Hose Clamp Position
    G05773227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL PURGE VSV 
    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.

      HINT

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

      Fig 3: Identifying Purge VSV Hose Clamp Position
      G05773228Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the VSV connector
  4. INSTALL WATER BY-PASS PIPE HOSE 
    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.

      HINT:

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

      Fig 4: Identifying Water By-Pass Pipe Hose Position
      G05773229Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL THROTTLE BODY ASSEMBLY  (See INSTALLATION )
  6. INSTALL NO. 3 ENGINE COVER SUB-ASSEMBLY  (See INSTALLATION )
  7. INSTALL ENGINE MOTOR CABLE CLAMP BRACKET 
    1. Install the engine motor cable clamp bracket with the bolt.

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

      Fig 5: Locating Engine Motor Cable Clamp Bracket Bolt
      G05773221Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the wire harness clamp to the bracket.
  8. INSTALL FLEXIBLE HOSE BRACKET SUB-ASSEMBLY 
    1. Install the flexible hose bracket with the bolt.

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

      Fig 6: Locating Bolt And Flexible Hose Bracket
      G05773220Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the flexible hose to the bracket
  9. INSTALL INJECTOR DRIVER 
    1. Install the No. 1 engine cover to the intake manifold.
    2. 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) 

      Fig 7: Identifying Injector Driver Bolts And Nuts Tightening Sequence
      G05773232Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. 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. Fig 8: Connecting Injector Driver Connectors
      G05773233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the 3 wire harness clamps to the bracket.
  10. CONNECT ENGINE WIRE HARNESS 
    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.

      HINT.

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

      Fig 9: Locating Ground Cable And Wire Harness Bracket
      G05773234Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. CONNECT ECM CONNECTOR 
    1. Connect the engine wire harness to the ECM box and connect the 4 ECM connectors.
      Fig 10: Locating ECM Connectors
      G05773216Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL NO. 2 CONNECTOR HOLDER 
    1. Attach the No. 2 connector holder.
      2. Fig 11: Identifying No. 2 Connector Holders
      G05773215Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Attach the wire harness's clamp A to the ECM box.
    3. Connect the 3 connectors.
  13. CONNECT HYBRID VEHICLE CONTROL ECU CONNECTOR 
    1. Connect the connector to the hybrid vehicle control ECU.
      2. Fig 12: Locating Hybrid Vehicle Control ECU Connector
      G05773214Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL OUTLET ENGINE ROOM ECM DUCT  (See INSTALLATION )
  15. INSTALL ENGINE ROOM ECU COVER  (See INSTALLATION )
  16. INSTALL NO. 6 COVER SUB-ASSEMBLY  (See INSTALLATION )
  17. INSTALL ENGINE COVER SUB-ASSEMBLY LH  (See INSTALLATION )
  18. INSTALL SKID CONTROL ECU BRACKET  (See INSTALLATION )
  19. CONNECT BRAKE FLUID RESERVOIR  (See INSTALLATION )
  20. CONNECT NO. 3 RELAY BLOCK  (See INSTALLATION )
  21. INSTALL SKID CONTROL ECU  (See INSTALLATION )
  22. CONNECT NO. 1 MOTOR COOLING PIPE  (See INSTALLATION )
  23. INSTALL AIR CLEANER ASSEMBLY RH  (See INSTALLATION  )
  24. INSTALL AIR CLEANER ASSEMBLY LH  (See INSTALLATION  )
  25. INSTALL INTAKE AIR CONNECTOR PIPE  (See INSTALLATION )
  26. INSTALL SERVICE PLUG GRIP  (See INSPECTION )
  27. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (see INITIALIZATION ).
  28. INSTALL BATTERY SERVICE HOLE COVER LH  (See INSTALLATION )
  29. INSTALL LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY  (See INSTALLATION )
  30. ADD ENGINE COOLANT  (See REPLACEMENT )
  31. INSPECT FOR COOLANT LEAK  (See ON-VEHICLE INSPECTION )
  32. CHECK FUNCTION OF THROTTLE BODY  (See ON-VEHICLE INSPECTION )
  33. CHECK AND CLEAR DTC  (See INSTALLATION )
  34. PERFORM TEST MODE INSPECTION  (See INSTALLATION )
  35. INSTALL NO. 1 ENGINE UNDER COVER  (See INSTALLATION )
  36. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH  (See INSTALLATION )
  37. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH  (See INSTALLATION )
  38. INSTALL NO. 1 AIR CLEANER INLET  (See INSTALLATION )
  39. INSTALL ENGINE ROOM SIDE COVER LH  (See INSTALLATION )
  40. INSTALL ENGINE ROOM SIDE COVER RH  (See INSTALLATION )
  41. INSTALL AIR CLEANER INLET COVER SUB-ASSEMBLY  (See INSTALLATION )
  42. INSTALL V-BANK COVER SUB-ASSEMBLY  (See INSTALLATION )
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