Toyota Avalon (XX50): Intake Manifold

Toyota Avalon (XX50) 2019-2022 Service & Repair Manual / Engine / 2gr-fks Intake / Exhaust / Intake Manifold

Components

COMPONENTS

ILLUSTRATION

*1	FRONT CENTER UPPER SUSPENSION BRACE SUB-ASSEMBLY	-	-
	Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : Nm (kgfcm, ft.*lbf)		Nm (kgfcm, ft.*lbf): Specified torque

ILLUSTRATION

*1	VENTILATION HOSE	*2	PURGE VALVE (PURGE VSV)
*3	NO. 1 FUEL VAPOR FEED HOSE	*4	NO. 2 SURGE TANK STAY
*5	INTAKE AIR SURGE TANK ASSEMBLY	*6	AIR SURGE TANK TO INTAKE MANIFOLD GASKET
*7	VACUUM HOSE SUB-ASSEMBLY	*8	VACUUM HOSE
*9	NO. 2 AIR TUBE	*10	NO. 1 V-BANK COVER BRACKET
*11	V-BANK COVER SUB-ASSEMBLY	*12	PLUG
	Nm (kgfcm, ft.*lbf): Specified torque	●	Non-reusable part
	Do not apply lubricants (to the threaded parts)	-	-

ILLUSTRATION

*1	STUD BOLT	*2	NO. 1 INTAKE MANIFOLD TO HEAD GASKET
*3	INTAKE MANIFOLD	*4	INJECTOR VIBRATION INSULATOR
*5	NO. 1 DELIVERY PIPE SPACER	*6	FUEL DELIVERY PIPE WITH SENSOR ASSEMBLY
*7	FUEL TUBE SUB-ASSEMBLY	*8	NO. 2 ENGINE MOUNTING STAY RH
*9	WIRE HARNESS CLAMP BRACKET	*10	NO. 5 ENGINE WIRE
	Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": Nm (kgfcm, ft.*lbf)		Nm (kgfcm, ft.*lbf): Specified torque
●	Non-reusable part

Installation

INSTALLATION

PROCEDURE

1. INSTALL STUD BOLT

HINT:

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

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

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

2. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET

(a) Install 2 new No. 1 intake manifold to head gaskets to each cylinder head sub-assembly.

NOTICE:

Align the port holes of the No. 1 intake manifold to head gaskets and cylinder head sub-assembly.
Make sure that the No. 1 intake manifold to head gaskets are installed in the correct direction.

3. INSTALL INTAKE MANIFOLD

(a) Temporarily install the intake manifold to the cylinder head sub-assembly with the 4 bolts and 4 nuts.

(b) Tighten the 4 bolts and 4 nuts in the order shown in the illustration.

	Bolt
	Nut

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

4. INSTALL INJECTOR VIBRATION INSULATOR

Click here

5. INSTALL NO. 1 DELIVERY PIPE SPACER

Click here

6. INSTALL FUEL DELIVERY PIPE WITH SENSOR ASSEMBLY

Click here

7. CONNECT FUEL TUBE SUB-ASSEMBLY

Click here

8. INSTALL NO. 2 ENGINE MOUNTING STAY RH

(a) Install the No. 2 engine mounting stay RH to the intake manifold and front No. 1 engine mounting bracket LH with the bolt.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

(b) Install the No. 2 engine mounting stay RH to the engine mounting insulator sub-assembly RH with the bolt and 2 nuts.

	Bolt
	Nut

Torque:

20 N·m {204 kgf·cm, 15 ft·lbf}

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(d) Connect the wire harness clamp to the wire harness clamp bracket with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

9. INSTALL NO. 1 V-BANK COVER BRACKET

HINT:

Perform this procedure only when replacement of the No. 1 V-bank cover bracket is necessary.

(a) Install the 2 No. 1 V-bank cover brackets to the intake air surge tank assembly.

Torque:

9.0 N·m {92 kgf·cm, 80 in·lbf}

10. INSTALL AIR SURGE TANK TO INTAKE MANIFOLD GASKET

(a) Install a new air surge tank to intake manifold gasket to the intake air surge tank assembly.

11. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

NOTICE:

Do not apply oil to the bolts and nuts as listed below:

Oil Application Prohibited Bolt and Nut
Bolt and Nut for Intake Air Surge Tank Assembly and Intake Manifold

(a) Install the plug to the intake air surge tank assembly.

(b) Temporarily install the intake air surge tank assembly to the intake manifold with the 5 bolts and 2 nuts.

(c) Temporarily install the No. 2 surge tank stay to the intake air surge tank assembly and camshaft housing RH with the 2 bolts.

(d) Tighten the 5 bolts and 2 nuts in the order shown in the illustration.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

	Bolt
	Nut

(e) Tighten the 2 bolts in the order shown in the illustration.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

(f) Engage the clamp to connect the No. 2 air tube to the intake air surge tank assembly.

*1	Vacuum Hose Sub-assembly
*2	Vacuum Hose
*3	No. 2 Air Tube

(g) Engage the clamp to connect the vacuum hose to the intake air surge tank assembly.

(h) Engage the 2 clamps to connect the vacuum hose sub-assembly to the intake air surge tank assembly.

(i) Engage the 2 clamps to connect the vacuum hose sub-assembly to the intake air surge tank assembly.

(j) Connect the vacuum switching valve (for ACIS) connector.

12. CONNECT PURGE VALVE (PURGE VSV)

(a) Connect the purge valve (purge VSV) to the intake air surge tank assembly with the bolt.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

(b) Connect the No. 1 fuel vapor feed hose to the intake air surge tank assembly.

13. CONNECT VENTILATION HOSE

(a) Connect the ventilation hose to the intake air surge tank assembly and slide the clip to secure it.

14. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

Click here

15. INSTALL FRONT CENTER UPPER SUSPENSION BRACE SUB-ASSEMBLY

Click here

16. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

Click here

17. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

Click here

18. INSPECT FOR FUEL LEAK

Click here

19. INSTALL V-BANK COVER SUB-ASSEMBLY

Click here

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
*: When performing learning using the Techstream. Click here
Battery terminal is disconnected/reconnected	Perform steering sensor zero point calibration	Lane departure alert system (w/ Steering Control)
		Pre-collision system
		Intelligent clearance sonar system*
		Lighting System (for Gasoline Model with Cornering Light)
	Memorize steering angle neutral point	Parking assist monitor system
	Memorize steering angle neutral point	Panoramic view monitor system
Replacement of fuel injector assembly Replacement of fuel pressure sensor (fuel delivery pipe with sensor assembly) Replacement of throttle body with motor assembly Cleaning the deposits from the throttle body with motor assembly	Inspection after repair	Poor idle, etc. Engine start function, etc.

PROCEDURE

1. PRECAUTION

NOTICE:

After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

Click here

2. DISCHARGE FUEL SYSTEM PRESSURE

Click here

3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

Click here

4. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

Click here

5. REMOVE FRONT CENTER UPPER SUSPENSION BRACE SUB-ASSEMBLY

Click here

6. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

Click here

7. REMOVE V-BANK COVER SUB-ASSEMBLY

Click here

8. DISCONNECT VENTILATION HOSE

(a) Slide the clip and disconnect the ventilation hose from the intake air surge tank assembly.

9. DISCONNECT PURGE VALVE (PURGE VSV)

(a) Disconnect the No. 1 fuel vapor feed hose from the intake air surge tank assembly.

(b) Remove the bolt and disconnect the purge valve (purge VSV) from the intake air surge tank assembly.

10. REMOVE NO. 2 SURGE TANK STAY

(a) Remove the 2 bolts and No. 2 surge tank stay from the intake air surge tank assembly and camshaft housing RH.

11. REMOVE INTAKE AIR SURGE TANK ASSEMBLY

(a) Disconnect the vacuum switching valve (for ACIS) connector.

(b) Disengage the 2 clamps to disconnect the vacuum hose sub-assembly from the intake air surge tank assembly.

*1	Vacuum Hose Sub-assembly
*2	Vacuum Hose
*3	No. 2 Air Tube

(d) Disengage the clamp to disconnect the vacuum hose from the intake air surge tank assembly.

(e) Disengage the clamp to disconnect the No. 2 air tube from the intake air surge tank assembly.

(f) Remove the 5 bolts, 2 nuts and intake air surge tank assembly from the intake manifold.

	Bolt
	Nut

(g) Remove the plug from the intake air surge tank assembly.

12. REMOVE AIR SURGE TANK TO INTAKE MANIFOLD GASKET

(a) Remove the air surge tank to intake manifold gasket from the intake air surge tank assembly.

13. REMOVE NO. 1 V-BANK COVER BRACKET

HINT:

Perform this procedure only when replacement of the No. 1 V-bank cover bracket is necessary.

(a) Remove the 2 No. 1 V-bank cover brackets from the intake air surge tank assembly.

14. REMOVE NO. 2 ENGINE MOUNTING STAY RH

(a) Remove the bolt and disconnect the wire harness clamp from the wire harness clamp bracket.

(b) Remove the bolt and separate the wire harness clamp bracket from the No. 2 engine mounting stay RH.

	Bolt
	Nut

(d) Remove the bolt and No. 2 engine mounting stay RH from the intake manifold and front No. 1 engine mounting bracket LH.

15. DISCONNECT FUEL TUBE SUB-ASSEMBLY

Click here

16. REMOVE FUEL DELIVERY PIPE WITH SENSOR ASSEMBLY

Click here

17. REMOVE NO. 1 DELIVERY PIPE SPACER

Click here

18. REMOVE INJECTOR VIBRATION INSULATOR

Click here

19. REMOVE INTAKE MANIFOLD

(a) Remove the 4 bolts, 4 nuts and intake manifold from the cylinder head sub-assembly.

	Bolt
	Nut

20. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET

(a) Remove the 2 No. 1 intake manifold to head gaskets from each cylinder head sub-assembly.

21. REMOVE STUD BOLT

HINT:

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

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

Intake Air Control Valve(for Acis)

Intake System

See More:

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