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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 15 (Engine Intake / Exhaust System (A25A-FXS) - Service Information) >> Intake Manifold >> Installation [10/2021 - ] >> Procedure

Installation [10/2021 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. INSTALL VACUUM HOSE 
    1. Install the vacuum hose to the intake manifold.
  2. INSTALL NO. 1 ENGINE COVER 
    1. Install the No. 1 engine cover with the clip.
  3. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET 
    1. Install a new No. 1 intake manifold to head gasket to the intake manifold.
  4. INSTALL INTAKE MANIFOLD 
    1. w/o Stud Bolt:
      1. Temporarily install the intake manifold to the cylinder head sub-assembly with the 5 bolts.
        GTY878743Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Tighten the 5 bolts in the order shown in the illustration.

        Torque: 24 N.m (245 kgf/cm, 18 ft.lbf) 

    2. w/ Stud Bolt:
      1. Temporarily install the intake manifold to the cylinder head sub-assembly.
        GTY928042Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Using an E8 "TORX" socket wrench, install the 2 stud bolts.

        Torque: 6.5 N.m (66 kgf/cm, 58 in.lbf) 

      3. Temporarily install the 3 bolts and 2 nuts.
        GTY856106Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Tighten the 3 bolts and 2 nuts in the order shown in the illustration.

        Torque: 24 N.m (245 kgf/cm, 18 ft.lbf) 

  5. INSTALL NO. 2 FUEL VAPOR FEED HOSE 
    1. Install the No. 2 fuel vapor feed hose to the intake manifold.
  6. INSTALL NO. 2 WATER BY-PASS PIPE 
    1. Temporarily install the No. 2 water by-pass pipe to the cylinder block sub-assembly with the bolt (B).
      GTY932569Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using an 8 mm socket wrench, temporarily install the No. 2 water by-pass pipe to the intake manifold with the 2 bolts (A).
    3. Tighten the bolt (B).

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

    4. Using an 8 mm socket wrench, tighten the 2 bolts (A).

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

    5. Engage the wire harness clamp to connect the HV air conditioning wire.
  7. CONNECT NO. 3 WATER BY-PASS PIPE 
    1. Using an 8 mm socket wrench, connect the No. 3 water by-pass pipe to the intake manifold with the bolt.

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

    2. Connect the No. 5 water by-pass hose to the No. 3 water by-pass pipe and slide the clip to secure it.
  8. CONNECT ENGINE WIRE 
    1. Engage the wire harness clamp to connect the engine wire to the intake manifold.
      GTY880686Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the bolt.

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

    3. Connect the engine wire to the cylinder head sub-assembly with the bolt.

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

      GTY880685Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the No. 5 engine wire connector.
  9. INSTALL PURGE VALVE (PURGE VSV) 

    Refer to INSTALLATION [12/2019 - ]

  10. INSTALL E.F.I. VACUUM SENSOR ASSEMBLY (MANIFOLD ABSOLUTE PRESSURE SENSOR) 

    Refer to PROCEDURE - Step 1

  11. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  12. CONNECT ENGINE WIRE 

    Refer to PROCEDURE - Step 5

  13. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to INSTALLATION [09/2020 - ]

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