Intake Manifold: Installation: Installation

WARNING: This page is about a different car, the 2010 Toyota FJ Cruiser. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL INTAKE MANIFOLD
1. Set a new gasket on each cylinder head.
  
  Fig 1: Identifying Intake Manifold Cylinder Hear & Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Align the port holes of the gasket and cylinder head.
  - Be careful of the installation direction.
2. Set the intake manifold on the cylinder heads.
3. Install and uniformly tighten the 6 bolts and 4 nuts in several passes.
  
  Fig 2: Identifying Intake Manifold, Cylinder Heads, Bolts & Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *1 Nut
  
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
  
  HINT:
  
  Tighten the inner installation bolts of the intake manifold before tightening the outer bolts.
INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY . Refer toINSTALLATION - Step 2
CONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY . Refer toINSTALLATION - Step 3
CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY . Refer toINSTALLATION - Step 4
INSTALL REAR CYLINDER HEAD COVER . Refer toINSTALLATION - Step 5

INSTALL INTAKE AIR SURGE TANK

Install a new gasket to the intake air surge tank.

Install the intake air surge tank in the order shown in the illustration.

Using a 8 mm socket hexagon wrench, temporarily tighten the 4 bolts to the intake air surge tank.

Fig 3: Identifying Intake Air Surge Tank & Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Temporarily tighten the 2 nuts to the intake air surge tank.

TEXT IN ILLUSTRATION

Nut

Tighten the 4 bolts and 2 nuts.
Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)

Install the No. 2 surge tank stay with the 2 bolts in the order shown in the illustration.

Fig 4: Identifying 2 Surge Tank Stay Bolt Installation Order
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
Install the No. 1 surge tank stay with the 2 bolts in the order shown in the illustration.

Fig 5: Identifying No. 1 Surge Tank Stay Bolt Installation Order
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
Engage the wire harness clamp.
Install the throttle body bracket with the 2 bolts in the order shown in the illustration.

Fig 6: Identifying Throttle Body Bracket Bolt Installation Order
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
Connect the No. 1 ventilation hose.

Fig 7: Identifying No. 1 Ventilation Hose & Clamp Dimensions
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
TEXT IN ILLUSTRATION

*a Front

Connect the No. 1 vacuum switching valve connector.

Fig 8: Identifying No. 1 Vacuum Switching Valve Connector & Clamp Dimensions

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*a	Front
*b	Matchmark
*c	Top

Connect the No. 1 fuel feed hose.
HINT:

Connect the hose so that the direction of the hose clamp is as indicated in the illustration.
Connect the throttle body connector.

Connect the No. 4 water by-pass hose.

Fig 9: Identifying Direction Of Throttle Body Connector & No. 4 Water By-Pass Hose Clamp

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*a	RH
*b	Rear
*c	Top
*d	Matchmark

HINT:

Connect the hose so that the direction of the hose clamp is as indicated in the illustration.

Connect the No. 5 water by-pass hose.
HINT:

Connect the hose so that the direction of the hose clamp is as indicated in the illustration.
Connect the 2 heater hose clamps.

INSTALL AIR CLEANER HOSE ASSEMBLY

Install the air cleaner hose assembly with the 2 hose clamps.

Fig 10: Identifying Air Cleaner Hose Assembly & Clamps

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

TEXT IN ILLUSTRATION

*a	Protrusion
*b	Groove
*c	Top
*d	RH
*e	Front
*f	Paint mark of the hose

Install the bolt.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
Connect the vacuum hose and ventilation hose.
HINT:

Connect the hose so that the direction of the hose clamp is as indicated in the illustration.
Engage the wire harness clamp.

ADD ENGINE COOLANT . Refer toREPLACEMENT - Step 2
INSPECT FOR COOLANT LEAK . Refer toON-VEHICLE INSPECTION - Step 1
INSPECT FOR FUEL LEAK . Refer toON-VEHICLE INSPECTION - Step 1
INSTALL V-BANK COVER
1. Engage the 2 V-bank cover hooks to the bracket.
2. Align the 2 V-bank cover grommets with the 2 pins and press down on the V-bank cover to engage the pins.