Toyota Prius: Intake Manifold

• Removal
• Installation

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
Replacement of throttle body assembly Cleaning the deposits from the throttle body assembly	Inspection after repair	Poor idle, etc. Engine start function, etc.

Procedure		Part Name Code
1	RADIATOR SUPPORT OPENING COVER	53289A	-	-	-
2	THROTTLE BODY ASSEMBLY	22210	-	-	-
3	INLET NO. 2 AIR CLEANER	17752	-	-	-
4	AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY	17801	-	-	-
5	AIR CLEANER CASE SUB-ASSEMBLY	17701	-	-	-
6	AIR CLEANER BRACKET	17771A	-	-	-
7	INLET NO. 1 AIR CLEANER	17751	-	-	-
8	EGR PIPE ASSEMBLY	25610	-	-	-
9	E.F.I. VACUUM SENSOR ASSEMBLY (MANIFOLD ABSOLUTE PRESSURE SENSOR)	89421	-	-	-
10	VENTILATION HOSE	12261	-	-	-
11	ENGINE WIRE	82121	-	-	-
12	ENGINE COVER BRACKET	-	-	-	-
13	NO. 8 WATER BY-PASS HOSE	16296	-	-	-
14	NO. 2 FUEL VAPOR FEED HOSE	23827A	-	-	-
15	WATER BY-PASS HOSE	-	-	-	-
16	INTAKE MANIFOLD	17111	-	-	-
17	NO. 1 INTAKE MANIFOLD TO HEAD GASKET	17177	-	-	-
18	STUD BOLT	-		-	-

*A	w/ Stud Bolt	-	-
●	Non-reusable part	-	-

PROCEDURE

1. REMOVE RADIATOR SUPPORT OPENING COVER

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2. REMOVE THROTTLE BODY ASSEMBLY

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3. REMOVE INLET NO. 2 AIR CLEANER

4. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

5. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

6. REMOVE AIR CLEANER BRACKET

7. REMOVE INLET NO. 1 AIR CLEANER

8. REMOVE EGR PIPE ASSEMBLY

9. REMOVE E.F.I. VACUUM SENSOR ASSEMBLY (MANIFOLD ABSOLUTE PRESSURE SENSOR)

10. DISCONNECT VENTILATION HOSE

11. DISCONNECT ENGINE WIRE

12. DISCONNECT ENGINE COVER BRACKET

13. DISCONNECT NO. 8 WATER BY-PASS HOSE

14. DISCONNECT NO. 2 FUEL VAPOR FEED HOSE

15. DISCONNECT WATER BY-PASS HOSE

*1

Water By-pass Hose

*2

No. 2 Water By-pass Hose

16. REMOVE INTAKE MANIFOLD

Bolt

Nut

17. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET

18. REMOVE STUD BOLT (w/ Stud Bolt)

HINT: If a stud bolt is deformed or the threads are damaged, replace it.

(1) Using an E6 "TORX" socket wrench, remove the 2 stud bolts from the intake manifold.

Installation

INSTALLATION

CAUTION / NOTICE / HINT

Procedure		Part Name Code
1	STUD BOLT	-		-	-
2	NO. 1 INTAKE MANIFOLD TO HEAD GASKET	17177	-	-	-
3	INTAKE MANIFOLD	17111		-	-
4	WATER BY-PASS HOSE	-	-	-	-
5	NO. 2 FUEL VAPOR FEED HOSE	23827A	-	-	-
6	NO. 8 WATER BY-PASS HOSE	16296	-	-	-
7	ENGINE COVER BRACKET	-	-	-	-
8	ENGINE WIRE	82121	-	-	-
9	VENTILATION HOSE	12261	-	-	-
10	E.F.I. VACUUM SENSOR ASSEMBLY (MANIFOLD ABSOLUTE PRESSURE SENSOR)	89421	-	-	-
11	EGR PIPE ASSEMBLY	25610		-	-
12	INLET NO. 1 AIR CLEANER	17751	-	-	-
13	AIR CLEANER BRACKET	17771A	-	-	-
14	AIR CLEANER CASE SUB-ASSEMBLY	17701	-	-	-
15	AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY	17801	-	-	-
16	INLET NO. 2 AIR CLEANER	17752	-	-	-
17	THROTTLE BODY ASSEMBLY	22210	-	-	-
18	RADIATOR SUPPORT OPENING COVER	53289A	-	-	-

*A	w/ Stud Bolt	-	-
	N*m (kgf*cm, ft.*lbf): Specified torque	●	Non-reusable part

PROCEDURE

1. INSTALL STUD BOLT (w/ Stud Bolt)

HINT: If a stud bolt is deformed or the threads are damaged, replace it.

(1) Using an E6 "TORX" socket wrench, install the 2 stud bolts to the intake manifold.

Torque:

5.0 N·m {51 kgf·cm, 44 in·lbf}

2. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET

3. INSTALL INTAKE MANIFOLD

bolt

nut

(b) Temporarily install the intake manifold to the cylinder head sub-assembly with the 3 bolts and 2 nuts.

(c) Tighten the 3 bolts and 2 nuts in the order shown in the illustration.

Torque:

28 N·m {286 kgf·cm, 21 ft·lbf}

4. CONNECT WATER BY-PASS HOSE

*1

Water By-pass Hose

*2

No. 2 Water By-pass Hose

5. CONNECT NO. 2 FUEL VAPOR FEED HOSE

6. CONNECT NO. 8 WATER BY-PASS HOSE

7. CONNECT ENGINE COVER BRACKET

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

8. CONNECT ENGINE WIRE

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

9. CONNECT VENTILATION HOSE

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

Torque:

7.0 N·m {71 kgf·cm, 62 in·lbf}

11. INSTALL EGR PIPE ASSEMBLY

*a	Claw	*b	Groove
*c	Protrusion	-	-

(1) Install a new EGR pipe gasket to the EGR valve assembly.

NOTICE:

Make sure that the claws of the EGR valve gasket are toward the EGR valve assembly side.

(2) Install a new inlet EGR gasket to the intake manifold.

NOTICE:

Align the protrusion of the inlet EGR gasket with the groove of the intake manifold.

(3) Install the EGR pipe assembly to the intake manifold and EGR valve assembly with the 4 bolts.

Torque:

8.5 N·m {87 kgf·cm, 75 in·lbf}

12. INSTALL INLET NO. 1 AIR CLEANER

Torque:

4.0 N·m {41 kgf·cm, 35 in·lbf}

13. INSTALL AIR CLEANER BRACKET

Torque:

12 N·m {122 kgf·cm, 9 ft·lbf}

14. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

Torque:

4.0 N·m {41 kgf·cm, 35 in·lbf}

15. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

16. INSTALL INLET NO. 2 AIR CLEANER

*a

Groove

*b

Protrusion

(1) Temporarily install the inlet No. 2 air cleaner to the inlet No. 1 air cleaner and upper radiator support sub-assembly with the bolts.

(2) Align the protrusion of the inlet No. 1 air cleaner with the groove of the inlet No. 2 air cleaner.

(3) Tighten the bolts.

Torque:

4.0 N·m {41 kgf·cm, 35 in·lbf}

(4) Install the clip

17. INSTALL THROTTLE BODY ASSEMBLY

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18. INSTALL RADIATOR SUPPORT OPENING COVER