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Intake Manifold: Installation

  1. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET 
    1. Install 2 new gaskets to the cylinder head as shown in the illustration.

      HINT:

      Make sure the white paint marks are facing upward.

      Fig 1: Installing No. 1 Intake Manifold To Head Gasket
      G05289283Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL INTAKE MANIFOLD 
    1. Install the intake manifold with the 6 bolts and 4 nuts.

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

    2. Connect the 8 injector connectors.
    3. Disconnect the ventilation hose.
    4. Connect the air hose for the power steering.
    5. Connect the vacuum hose for the brake booster.
      Fig 2: Locating Intake Manifold With Bolts And Nuts
      G05289284Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY 
    1. Using SST, install the fuel pipe.

      SST 09023-38401 

      Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf) for use without SST 

      28 N*m (286 kgf*cm, 21 ft.*lbf) for use with SST 

      HINT:

      Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

      Fig 3: Installing No. 2 Fuel Pipe Sub-Assembly
      G05289285Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL PURGE VSV 
    1. Install the purge VSV with the bolt.

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

    2. Connect the 2 hoses for the purge VSV.
    3. Connect the purge VSV connector.
  5. INSTALL NO. 4 V-BANK COVER BRACKET 
    1. Install the cover bracket with the 2 nuts.

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

  6. INSTALL NO. 3 V-BANK COVER BRACKET 
    1. Install the cover bracket with the bolt.

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

  7. INSTALL NO. 2 V-BANK COVER BRACKET 
    1. Install the cover bracket with the bolt.

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

  8. INSTALL NO. 1 V-BANK COVER BRACKET 
    1. Install the cover bracket with the bolt.

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

  9. INSTALL THROTTLE BODY ASSEMBLY (See  INSTALLATION  ) 
  10. INSTALL INTAKE AIR CONNECTOR PIPE 
    1. Install the intake air connector pipe with the bolt and hose clamp.

      Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) for hose clamp 

      5.0 N*m (51 kgf*cm, 44 in.*lbf) for bolt 

    2. Connect the air hose and ventilation hose together.
  11. CHECK FOR FUEL LEAKS (See  ON-VEHICLE INSPECTION  ) 
  12. INSTALL V-BANK COVER 
    1. Install the V-bank cover with the 2 nuts.

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

  13. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  14. PERFORM INITIALIZATION 
    1. Perform initialization (see INITIALIZATION ).
      NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
  15. ADD ENGINE COOLANT (See  COOLANT  ) 
  16. CHECK FOR ENGINE COOLANT LEAKS (See  COOLING SYSTEM  ) 
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