Installation

2UZ-FE INTAKE: INTAKE MANIFOLD:

INSTALLATION

1. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY (Installation)

2. INSTALL VACUUM SWITCHING VALVE ASSEMBLY (for ACIS) (Installation)

3. INSTALL PURGE VSV





(a) Install the VSV with the bolt to the intake manifold.
Torque: 18 Nm (184 kgf-cm, 13 ft-lbf)
(b) Connect the purge line hose to the intake manifold.
4. INSTALL NO. 1 VENTILATION HOSE
5. INSTALL THROTTLE BODY ASSEMBLY





(a) Align the protrusion of a new gasket with the groove of the intake manifold, and install the gasket.





(b) Install the throttle body with the nut and 3 bolts.
Torque: 14 Nm (143 kgf-cm, 10 ft-lbf)
6. INSTALL INTAKE MANIFOLD ASSEMBLY





(a) Place 2 new gaskets on the intake manifold.
(b) Place the intake manifold on the cylinder heads.





(c) Install and uniformly tighten the 6 bolts and 4 nuts in several steps.
Torque: 18 Nm (184 kgf-cm, 13 ft-lbf)





(d) Install the engine wire protector with the 2 bolts.
Torque: 8.2 Nm (83 kgf-cm, 72 in-lbf)
(e) Connect the 8 injector connectors.





(f) Connect the 2 wire clamps to the wire clamp brackets on the RH delivery pipe.





(g) Connect the VSV connector (for ACIS).





(h) Install the wire bracket to the intake manifold with the bolt.
Torque: 8.2 Nm (83 kgf-cm, 72 in-lbf)
(1) Connect the engine wire to the wire bracket and engine hanger.





(i) Connect the purge line hose to the purge VSV.
(j) Connect the purge VSV connector.





(k) Connect the No. 1 ventilation hose to the ventilation valve on the LH cylinder head.





(l) Connect the 2 water by-pass hoses to the throttle body.
(m) Connect the throttle position sensor and control motor connector.
7. INSTALL FUEL MAIN TUBE (Installation)

8. INSTALL FUEL RETURN TUBE (Installation)

9. INSTALL NO. 2 WATER BY-PASS PIPE





(a) Connect the 2 hoses to the water by-pass pipe.
(b) Install the No. 2 water by-pass pipe with the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)





(c) Connect the 2 water hoses.
10. INSTALL VACUUM HOSE ASSEMBLY





(a) Connect the hose to the intake manifold.
(b) Install the vacuum hose assembly with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
11. INSTALL AIR CLEANER HOSE ASSEMBLY





(a) Install the air cleaner hose.
Torque: 4.0 Nm (41 kgf-cm, 35 in-lbf)

HINT: Make sure that the clamp band end is aligned with the limit mark when the hose clamps is tightened, as indicated by A and B in the illustration.

(b) Connect the vacuum hose and No. 2 ventilation hose.
12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTE: Some systems need to be initialized after the cable is reconnected (Repair Instruction - Initialization).

13. ADD ENGINE COOLANT (Service and Repair)

14. INSPECT FOR COOLANT LEAK (Testing and Inspection)

15. INSPECT FOR FUEL LEAK (Installation)

16. INSTALL NO. 1 ENGINE UNDER COVER (Replacement)

17. INSTALL THROTTLE BODY COVER SUB-ASSEMBLY





(a) Install the 2 throttle body cover brackets with the 2 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)





(b) Install the throttle body cover with the 2 cap nuts.
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)
18. INSTALL FRONT COWL TOP OUTER PANEL SUB-ASSEMBLY
(a) Install the outer panel with the 7 bolts.





Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)
(b) Connect the 2 washer hoses.
19. INSTALL FRONT WIPER MOTOR AND LINK
(a) For the front wiper motor and link, refer to the following procedures (Installation).