Toyota Yaris: Intake Manifold / Installation

INSTALLATION

PROCEDURE

1. INSTALL MANIFOLD TO CYLINDER HEAD GASKET

(a) Install a new No. 1 intake manifold to head gasket to the intake manifold.

2. INSTALL THROTTLE WITH THROTTLE POSITION SENSOR BODY ASSEMBLY

(a) Install the new gaskets to throttle with throttle position sensor body assembly.

(b) Install the throttle with throttle position sensor body assembly to intake manifold.

3. INSTALL AIR TUBE ASSEMBLY

(a) Install the new gaskets to air tube assembly.

(b) Install the air tube assembly to the intake manifold with the 4 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

4. INSTALL NO. 1 FUEL VAPOR FEED HOSE

(a) Engage the 2 clamps to install the air tube assembly to the intake manifold.

5. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET

(a) Install the new gaskets to the cylinder head sub-assembly.

6. INSTALL NO. 1 VENTILATION FLANGE SEPARATOR

(a) Install the No. 1 ventilation flange separator to the cylinder head sub-assembly.

7. INSTALL INTAKE MANIFOLD

(a) Install the No. 5 air hose to the air tube and tighten the hose clamp.

Torque:

3.0 N·m {31 kgf·cm, 27 in·lbf}

(b) Tighten the 2 bolts and 2 nuts in the order shown in the illustration.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

*a	Rear of Vehicle
*b	Top of Vehicle
*c	30°
	Bolt
	Nut
	Clamp

8. INSTALL INTAKE AIR CONNECTOR BRACKET

(a) Install the intake air connector bracket to the intake manifold with the 2 bolts.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

9. INSTALL WATER BY-PASS HOSE

(a) Connect the No. 2 water by-pass hose and No. 3 water by-pass hose to the throttle body with motor assembly and slide the 2 clips to secure them.

10. CONNECT ENGINE WIRE

(a) Install the clamp.

(b) Install the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(c) Connect the connector.

11. INSTALL NO. 1 TURBO PRESSURE SENSOR

(a) Install the No. 1 turbo pressure sensor to the intake manifold with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

12. INSTALL WIRE HARNESS CLAMP BRACKET

(a) Install the wire harness clamp bracket to the intake manifold with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

13. CONNECT NO. 1 FUEL VAPOR FEED HOSE

(a) Connect the No. 1 fuel vapor feed hose to the vacuum switching valve assembly.

14. INSTALL ENGINE WIRE

(a) Engage the 3 clamps to install the engine wire to the intake manifold.

15. INSTALL NO. 4 WATER BY-PASS PIPE

(a) Install the No. 4 water by-pass pipe to the intake manifold with the 3 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(b) Connect the No. 7 water by-pass hose, No. 2 water by-pass hose, No. 1 water by-pass hose and slide the 3 clips to secure them.

16. INSTALL ENGINE WIRE

(a) Install the engine wire to the engine assembly with the bolt and nut.

Torque:

Bolt :

10 N·m {102 kgf·cm, 7 ft·lbf}

Nut :

9.8 N·m {100 kgf·cm, 87 in·lbf}

(b) Engage the 2 clamps and connect the 5 connectors to install the engine wire.

17. ADD ENGINE COOLANT

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18. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

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