Intake Manifold Installation

Using the E8 "TORX" socket wrench, install the 2 stud bolts.

Torque:

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

Set a new gasket on each cylinder head.

NOTICE:

1. Align the port holes of the gasket and cylinder head.
   
2. Be careful of the installation direction.
   

Set the intake manifold on the cylinder heads.

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

Torque:

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

HINT:

Tighten the inner installation bolts of the intake manifold before tightening the outer bolts.

Place the fuel delivery pipe together with the 6 fuel injectors on the intake manifold.

Temporarily install the 4 bolts, which are used to hold the fuel delivery pipe in place, to the intake manifold.

Check that the fuel injectors rotate smoothly.

Position the fuel injectors with the connectors facing outward.

Tighten the 4 bolts.

Torque:

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

Connect the 6 fuel injector connectors.

Install a new gasket to the intake air surge tank.

Install the intake air surge tank with the 4 bolts and 2 nuts in the order shown in the illustration.

Torque:

28 N*m{286 kgf*cm, 21 ft.*lbf}

Text in Illustration

	Bolt
	Nut

Install the throttle body bracket with the 2 bolts.

Torque:

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

Install the No. 1 surge tank stay with the 2 bolts.

Torque:

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

Attach the wire harness clamp.

Install the bracket with the bolt and attach the 2 wire harness clamps.

Torque:

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

Install the No. 2 surge tank stay with the 2 bolts.

Torque:

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

for Manual Transmission:
Connect the clutch flexible hose bracket with the nut.

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

Connect the No. 1 PCV hose.

HINT:

Connect the No. 1 PCV hose so that the direction of the hose clamp is as indicated in the illustration.

Connect the No. 1 vacuum switching valve connector.

Connect the purge line hose.

Connect the throttle body connector.

Connect the No. 4 water by-pass hose.

Connect the No. 5 water by-pass hose.

for Bank 1 Side:
Align the paint mark with the projection and connect the air tube assembly to the emission control valve set.

HINT:

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

for Bank 2 Side:
Align the paint mark with the projection and connect the air tube assembly to the No. 2 emission control valve set.

HINT:

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

Install the 3 bolts.

Torque:

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

Connect the No. 3 air hose.

Install the No. 1 air cleaner hose with the 2 hose clamps.

Torque:

2.5 N*m{25 kgf*cm, 22 in.*lbf}

Install the bolt.

Torque:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

Connect the vacuum hose and No. 2 PCV hose.

Add engine coolant.

Standard Capacity (for Manual transmission):

Item	Specified Condition
w/ Rear Heater	14.6 liters (15.4 US qts, 12.8 Imp. qts)
w/o Rear Heater	11.7 liters (12.4 US qts, 10.3 Imp. qts)

Standard capacity (for Automatic transmission):

11.2 liters (11.8 US qts, 9.9 Imp. qts)

Standard Capacity (for China):

14.4 liters (15.2 US qts, 12.7 Imp. qts)

NOTICE:

Do not substitute plain water for engine coolant.

HINT:

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 consists of a combination of low phosphates and organic acids).

Slowly pour coolant into the radiator reservoir until it reaches the F line.

Install the reservoir cap.

Press the No. 1 and No. 2 radiator hoses several times by hand, and then check the coolant level. If the coolant level is low, add coolant.

Install the radiator cap.

Set the air conditioning as follows while warming up the engine.

Start the engine and warm it up until the thermostat opens.

HINT:

The thermostat opening timing can be confirmed by pressing the No. 2 radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

Maintain the engine speed at 2000 to 2500 rpm.

NOTICE:

1. Make sure that the radiator reservoir still has some coolant in it.
   
2. Pay attention to the needle of the water temperature meter. Make sure that the needle does not show an abnormally high temperature.
   
3. If there is not enough coolant, the engine may burn out or overheat.
   
4. Immediately after starting the engine, if the radiator reservoir does not have any coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the coolant is filled to the F line.
   
5. Run the engine at 2000 rpm until the coolant level has stabilized.
   

Press the No. 1 and No. 2 radiator hoses several times by hand to bleed air.

CAUTION:

1. Wear protective gloves. Hot areas on the parts may injure your hands.
   
2. Be careful as the radiator hoses are hot.
   
3. Keep your hands away from the fan.
   

Stop the engine, and wait until the engine coolant cools down to ambient temperature.

CAUTION:

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

Check that the coolant level is between the F and L lines.
If the coolant level is below the L line, repeat all of the procedures above.
If the coolant level is above the F line, drain coolant so that the coolant level is between the F and L lines.

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

Warm up the engine.

Using the radiator cap tester, increase the pressure inside the radiator to 123 kPa (1.3 kgf/cm², 18 psi), and then check that the pressure does not drop.
If the pressure drops, check the hoses, radiator and engine water pump for leakage. If there are no signs or traces of external engine coolant leakage, check the heater core, cylinder block and head.

Make sure that there are no fuel leaks after performing maintenance on the fuel system.

1. Connect the GTS to the DLC3.
   

2. Turn the ignition switch to ON and turn the GTS on.
   

   NOTICE:

   Do not start the engine.

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

4. Check that there are no leaks from the fuel system.
   If there are fuel leaks, repair or replace parts as necessary.
   

5. Turn the ignition switch off.
   

6. Disconnect the GTS from the DLC3.
   

Attach the 2 V-bank cover hooks to the bracket. Then align the 2 V-bank cover grommets with the 2 pins and press down on the V-bank cover to attach the pins.

Install the No. 1 engine under cover with the 10 bolts.

Torque:

29 N*m{296 kgf*cm, 21 ft.*lbf}

Push in the clip to install the front fender splash shield sub-assembly LH.

Install the 3 bolts and screw.

Push in the clip to install the front fender splash shield sub-assembly RH.

Install the 3 bolts and 2 screws.