Toyota Yaris: Intake Manifold / Removal

Toyota Yaris XP210 (2020-2024) Reapir and Service Manual / Engine & Hybrid System / G16e-gts (intake / Exhaust) / Intake Manifold / Removal

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during intake manifold removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed	Link
Cleaning the deposits from the throttle body with motor assembly	Inspection After Repair	Poor idle, etc. Engine start function, etc.

PROCEDURE

1. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY

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2. DRAIN ENGINE COOLANT

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3. SEPARATE ENGINE WIRE

(a) Disconnect the 5 connectors and disengage the 2 clamps.

(b) Remove the bolt, nut and separate the engine wire from the engine assembly.

4. REMOVE NO. 4 WATER BY-PASS PIPE

(a) Slide the 3 clips and disconnect the No. 7 water by-pass hose, No. 2 water by-pass hose and No. 1 water by-pass hose.

	Bolt
	Clamp

(b) Remove the 3 bolts and No. 4 water by-pass pipe from the intake manifold.

5. SEPARATE ENGINE WIRE

(a) Disengage the 3 clamps to disconnect the engine wire from the intake manifold.

6. SEPARATE NO. 1 FUEL VAPOR FEED HOSE

(a) Separate the No. 1 fuel vapor feed hose assembly from the vacuum switching valve assembly.

7. REMOVE WIRE HARNESS CLAMP BRACKET

(a) Remove the 2 bolts and 2 brackets from the intake manifold.

8. REMOVE NO. 1 REMOVE TURBO PRESSURE SENSOR

(a) Remove the bolt and No. 1 turbo pressure sensor from the intake manifold.

9. REMOVE ENGINE WIRE

(a) Disconnect the connector.

(b) Remove the bolt.

10. REMOVE WATER BY-PASS HOSE

(a) Slide the 2 clips and disconnect the No. 2 water by-pass hose and No. 3 water by-pass hose to from the throttle body with motor assembly.

11. REMOVE INTAKE AIR CONNECTOR BRACKET

(a) Remove the 2 bolts and intake air connector bracket from the intake manifold.

12. REMOVE INTAKE MANIFOLD

(a) Loosen the hose clamp.

	Bolt
	Nut
	Clamp

(b) Remove the 2 bolts, 2 nuts and intake manifold from the No. 1 ventilation flange separator.

13. REMOVE NO. 1 VENTILATION FLANGE SEPARATOR

(a) Remove the No. 1 ventilation flange separator from the cylinder head sub-assembly.

14. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET

(a) Remove the No.1 intake manifold to head gasket from the cylinder head sub-assembly.

15. REMOVE NO. 1 FUEL VAPOR FEED HOSE

(a) Disengage 2 clamps and remove the No. 1 fuel vapor feed hose.

16. REMOVE AIR TUBE ASSEMBLY

(a) Remove the 2 bolts and air tube assembly.

17. REMOVE THROTTLE WITH THROTTLE POSITION SENSOR BODY ASSEMBLY

(a) Remove the throttle with throttle position sensor body assembly.

18. REMOVE MANIFOLD TO CYLINDER HEAD GASKET

(a) Remove the manifold to cylinder head gasket from the intake manifold.

Components

COMPONENTS ILLUSTRATION *1 NO. 1 ENGINE UNDER COVER ASSEMBLY *2 ENGINE WIRE *3 NO. 4 WATER BY-PASS PIPE *4 NO. 1 FUEL VAPOR FEED HOSE *5 WIRE HARNESS CLAMP BRACKET *6 E...

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...

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