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Intake Manifold: Installation

  1. INSTALL INTAKE MANIFOLD SUB-ASSEMBLY UPPER 
    1. Set 2 new gaskets on the cylinder head.
      Fig 1: Setting New Gaskets On Cylinder Head
      G04027973Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Make sure the white paint marks are facing upward.

    2. Install the intake manifold to the gasket and cylinder head with the 6 bolts and 4 nuts.

      Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

      Fig 2: Identifying Intake Manifold To Gasket And Cylinder Head
      G04027974Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the 8 injector connectors.
  2. CONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY 
    1. Connect the No. 2 fuel pipe (ON-VEHICLE INSPECTION ).
  3. CONNECT ENGINE WIRE 
    1. Install the wire protector (LH side) with the 3 bolts.
    2. Install the 2 wire clamps on the engine wire (RH side) to the brackets on the RH delivery pipe.
    3. Install the engine wire protector (rear side) to the rear water bypass joint and RH cylinder head with the 2 bolts.
      Fig 3: Identifying Engine Wire Protector To Rear Water By-Pass Joint And Rh Cylinder Head With 2 Bolts
      G04027975Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL NO. 3 V-BANK COVER BRACKET 
    1. Install the bracket to the manifold with the bolt, as shown in E in the illustration below.

      Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

    2. Connect the connector as shown in E in the illustration below.
  5. INSTALL NO. 2 V-BANK COVER BRACKET 
    1. Install the bracket to the manifold with the bolt, as shown in D in the illustration below.

      Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

  6. INSTALL VACUUM SWITCHING VALVE ASSEMBLY (for EVAP) 
    1. Install the bracket of the VSV to the manifold with the bolt, as shown in C in the illustration below.

      Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

    2. Connect the vacuum hose to the VSV, as shown in C in the illustration below.
    3. Connect the connector to the VSV, as shown in C in the illustration below.
  7. INSTALL V-BANK COVER BRACKET 
    1. Install the bracket to the manifold with the bolt, as shown in the illustration B below.

      Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

  8. INSTALL NO. 4 V-BANK COVER BRACKET 
    1. Install the bracket to the manifold with the 2 nuts, as shown in the illustration A below.

      Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

      Fig 4: Identifying Bracket To Manifold With 2 Nuts
      G04027976Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL THROTTLE BODY ASSEMBLY ( INSTALLATION  ) 
  10. INSTALL INTAKE AIR CONNECTOR PIPE ( INSTALLATION  ) 
  11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  12. CHECK FOR FUEL LEAKS 
    1. Check for fuel leaks (ON-VEHICLE INSPECTION ).
  13. ADD ENGINE COOLANT ( ON-VEHICLE INSPECTION  ) 
  14. CHECK FOR COOLANT LEAKS 
    1. Check for engine coolant leaks (ON-VEHICLE INSPECTION ).
  15. INSTALL V-BANK COVER SUB-ASSEMBLY 
    1. Install the cover with the 2 nuts.

      Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

  16. INSTALL ENGINE ROOM SIDE COVER LH ( INSTALLATION  ) 
  17. INSTALL ENGINE ROOM SIDE COVER RH ( INSTALLATION  ) 
  18. INSTALL AIR CLEANER INLET 
    1. Install the inlet with the bolt.

      Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

  19. INSTALL COOL AIR INTAKE DUCT SEAL ( INSTALLATION  ) 
  20. PERFORM INITIALIZATION 
    1. Perform initialization (INITIALIZATION ).
      NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
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