Intake Manifold Installation

Engine Hybrid System. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
2Tr-Fbe Intake Exhaust. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. INSTALL STUD BOLT

  2. INSTALL INTAKE MANIFOLD

  3. INSTALL PURGE VSV

  4. INSTALL FRONT UPPER FENDER APRON SEAL

  5. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

  6. INSTALL STARTER ASSEMBLY

  7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  8. INSPECT FOR FUEL LEAK (for Fuel Sub Tank)

Intake Manifold -- Installation



1. INSTALL STUD BOLT
NOTICE:
If a stud bolt is deformed or its threads are damaged, replace it.

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

    Torque:
    3.0 N*m{31 kgf*cm, 27 in.*lbf}


2. INSTALL INTAKE MANIFOLD

  1. Install the purge line hose to the intake manifold.

  1. Install the 2 wire harness clamp brackets to the intake manifold with the 2 bolts.

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

  1. Apply gasoline to 4 new O-rings. Then install the 4 O-rings to the No. 1 fuel pipe sub-assembly.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fbe Intake Exhaust.Intake System.Intake Manifold Installation

  1. Set the No. 1 fuel pipe sub-assembly against the 4 protrusions and install it with the 4 bolts.

    Torque:
    10 N*m{102 kgf*cm, 7 ft.*lbf}
    Text in Illustration
    *1
    		Paint Mark (White)
    NOTICE:
    1. Set the areas of the fuel pipe marked with white paint marks against the protrusions of the intake manifold from the directions indicated by the arrows in the illustration.
    2. Make sure the fuel pipe does not become deformed when installing it.

  1. Install a new gasket to the intake manifold.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fbe Intake Exhaust.Intake System.Intake Manifold Installation

  1. Install the intake manifold with the 5 bolts and 2 nuts, and tighten the bolts and nuts in the sequence shown in the illustration.

    Torque:
    25 N*m{255 kgf*cm, 18 ft.*lbf}
    Text in Illustration
    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
    		Bolt
    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
    		Nut

  1. Connect the No. 3 PCV hose and vacuum hose to the intake manifold.

  1. Attach the No. 2 water by-pass hose.

  1. Attach the No. 1 fuel hose to the intake manifold.

  1. Install the clamp.

  1. Attach the 3 wire harness clamps to the 2 wire harness clamp brackets.



3. INSTALL PURGE VSV

  1. Install the bracket with the bolt.

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


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fbe Intake Exhaust.Intake System.Intake Manifold Installation

  1. Install the purge VSV together with the bracket with the bolt.

    Torque:
    10 N*m{102 kgf*cm, 7 ft.*lbf}
    Text in Illustration
    *a
    		Front
    *b
    		Top

  1. Connect the 2 purge line hoses to the purge VSV.

  1. Connect the purge VSV connector.



4. INSTALL FRONT UPPER FENDER APRON SEAL

  1. Install the front upper fender apron seal with the 5 clips.



5. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY
(HILUX_TGN26 RM000000VWL023X.html)


6. INSTALL STARTER ASSEMBLY
(HILUX_TGN26 RM000000SGZ00WX.html)


7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected (HILUX_TGN26 RM000004QR3003X.html).


8. INSPECT FOR FUEL LEAK (for Fuel Sub Tank)

  1. Start the engine.

    NOTICE:
    Perform the inspection while the engine is cold.
    The fuel pump operates only for a calculated time when the coolant temperature is 20°C (68°F) or less and learned ethanol concentration is 85% or more.

  1. Check 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.