Intake Manifold: Installation

WARNING: This page is about a different variant/trim than selected.

INSTALL INTAKE AIR CONTROL VALVE ACTUATOR (for TCV) (See INSTALLATION )
INSTALL PURGE LINE HOSE
1. Attach the clamp to the intake manifold.
2. Install the purge line hose to the intake manifold.
3. Connect the purge line hose to the clamp.
  
  Fig 1: Locating Purge Line Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WIRING HARNESS CLAMP BRACKET
1. Install the bracket with the bolt.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL CHECK VALVE
1. Install the 2 vacuum hoses to the check valve.
  
  Fig 2: Identifying Wiring Harness Clamp Bracket Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the 2 vacuum hoses to the intake manifold to install the check valve.
  
  Fig 3: Locating Vacuum Hoses
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Check that the check valve is installed as shown in the illustration.
  
  Fig 4: Identifying Check Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL UNION TO CONNECTOR TUBE HOSE
1. Install the union to connector tube hose to the intake manifold.
  
  Fig 5: Locating Connector Tube Hose Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INTAKE MANIFOLD
1. Close the tumble control valves.
  NOTE: The valves may be damaged if they are not closed before installing the intake manifold.
  
  HINT:
  
  Connect the battery to the terminals of the actuator and operate the motor to close the valves (See ON-VEHICLE INSPECTION ).
  
  Fig 6: Identifying Tumble Control Valves Closed Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install a new gasket to the intake manifold.
  
  Fig 7: Identifying Tumble Control Valves Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the intake manifold with the 6 bolts in the sequence shown in the illustration.
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
  
  Fig 8: Identifying Intake Manifold With Bolts Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT NO. 2 VENTILATION HOSE
1. Connect the No. 2 ventilation hose to the intake manifold.
INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY (See INSTALLATION )

Fig 9: Locating No. 2 Ventilation Hose Clamps
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VACUUM SWITCHING VALVE ASSEMBLY (for ACIS)
1. Install the vacuum switching valve with the bolt.
  Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
2. Connect the 2 vacuum hoses and union to connector tube hose.
  
  Fig 10: Locating Vacuum Switching Valve Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT WIRE HARNESS
1. Attach the clamp and wire harness.
  
  Fig 11: Identifying Wire Harness Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the bracket with the bolt.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 12: Locating Bracket Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the intake air control actuator connector.
4. Attach the 2 clamps to the intake manifold and bracket.
5. Install the wire harness with the bolt.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 13: Locating Intake Air Control Valve Actuator Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Attach the 2 clamps.
7. Connect the 2 wire harness brackets with the 2 bolts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
8. Connect the 2 connectors.
9. Connect the 4 injector connectors.
INSTALL FUEL TUBE SUB-ASSEMBLY (See FUEL PRESSURE REGULATOR )
INSTALL THROTTLE BODY ASSEMBLY (See INSTALLATION )
INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See INSTALLATION )

Fig 14: Locating Wire Harness Brackets Clamp
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT HEATER HOSE
1. Connect the outlet heater water hose to the water by-pass pipe and heater radiator unit.
2. Connect the inlet heater water hose to the cylinder head and heater radiator unit.
  
  Fig 15: Locating Inlet Heater Water Hose Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL HOSE TO HOSE TUBE
1. Install the tube with the 2 nuts.
  Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
2. Connect the hose.
  
  Fig 16: Locating Hose Tube Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT UNION TO CONNECTOR TUBE HOSE
1. Connect the union to connector tube hose to the tube.
INSTALL COWL TOP OUTER PANEL SUB-ASSEMBLY
1. Install the cowl top outer panel with the 14 bolts.
  Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf)
  
  Fig 17: Locating Connector Tube Hose Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 18: Locating Cowl Top Outer Panel Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Attach the 3 clamps.
  
  Fig 19: Identifying Connector Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL COWL VENTILATOR HOUSING SUB-ASSEMBLY
1. Attach the 4 clamps to install the cowl ventilator housing.
INSTALL FRONT WIPER MOTOR AND LINK
1. Install the front wiper motor and link (See INSPECTION ).
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
ADD ENGINE COOLANT (See COOLANT )

Fig 20: Identifying Cowl Ventilator Housing Clamps
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT FOR COOLANT LEAK (See COOLING SYSTEM )
INSPECT FOR FUEL LEAK (See FUEL PRESSURE REGULATOR )
INSTALL NO. 1 ENGINE UNDER COVER (See ENGINE UNIT )
INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (See ECM )