Intake Manifold: Installation: Installation

INSTALL INTAKE AIR SURGE TANK ASSEMBLY
1. Install the union to check valve hose bracket with the bolt.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
2. Install the V-bank cover bracket sub-assembly with the bolt.
  
  Fig 1: Locating V-Bank Cover Bracket Sub-Assembly Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
3. Install 2 new gaskets to the intake air surge tank assembly.
4. Temporarily install the intake air surge tank assembly with the 2 nuts and 8 bolts. Then tighten the 2 nuts and 8 bolts uniformly in the order shown in the illustration.
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
  
  Fig 2: Locating Intake Air Surge Tank Assembly Bolts And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
1. Apply gasoline to 8 new O-ring and install one to each injector.
  NOTE:
  Check that there is no damage or foreign objects in the groove of the injector when installing the O-ring. If an injector falls out of the delivery pipe during removal or installation, reinstall the injector to the delivery pipe using a new O-ring between the injector and delivery pipe.
2. Install the injectors with delivery pipe assembly and 4 spacers with the 4 bolts.
  
  Fig 3: Locating Fuel Delivery Pipe Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
3. Install the 2 wire harnesses with the 4 bolts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL NO. 3 FUEL HOSE . Refer to INSTALLATION - Step 56
CONNECT VACUUM HOSE ASSEMBLY . Refer to INSTALLATION - Step 58
INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
1. Install the water by-pass pipe to the intake air surge tank assembly with the 2 bolts.
  
  Fig 4: Locating Water By-Pass Pipe Clamps And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
2. Connect the heater inlet water hose, heater outlet water hose, water inlet hose, water outlet hose, and water by-pass hose to the water by-pass pipe with the 5 clamps.
INSTALL INJECTOR DRIVER
1. Install the No. 2 V-bank cover bracket sub-assembly with the bolt.
  
  Fig 5: Locating Injector Driver And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
2. Install the 2 injector drivers with the 8 nuts.
  Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
3. Connect the 4 injector driver connectors to the injector driver.
  HINT:
  
  To connect the injector driver connectors, move the lock lever to lock the connector.
INSTALL VACUUM SWITCHING VALVE ASSEMBLY
1. Connect the ventilation hose.
  
  Fig 6: Locating Vacuum Switching Valve Assembly And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the vacuum switching valve assembly with the bolt.
  Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf)
3. Connect the No. 2 fuel vapor feed hose to the vacuum switching valve assembly.
4. Connect the fuel vapor feed hose to the intake air surge tank assembly.
CONNECT ENGINE WIRE
1. Connect the engine wire harness connector.
  HINT:
  
  To connect the injector driver connectors, move the lock lever to lock the connector.
  1. Connect the engine wire with the 4 nuts. (A)
    
    Fig 7: Locating Engine Wire Connectors And Nuts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  2. Connect the 4 connectors and 5 clamps. (B)
  3. Install the ground cable with the bolt. (C)
    Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf)
  4. Connect the 4 injector driver connectors. (D)
  5. Install the wire harness with the nut to the relay box. (E)
    Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  6. Connect the 9 connectors and 3 clamps. (F)
    
    Fig 8: Locating Engine Wire Connectors And Clamps
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. Install the wire harness with the nut to the +B terminal. (G)
    Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
  8. Connect the generator connector and 2 clamps. (H)
  9. Install the oil cooler tube sub-assembly withe the bolt and nut. (I)
    Bolt
    
    Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
    
    Nut
    
    Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf)
  10. Connect the 2 connectors and then install the nut. (J)
    Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  11. Connect the starter connector. (K)
  12. Install the 2 bolts to the No. 3 exhaust manifold heat insulator. (L)
    Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL OIL COOLER TUBE SUB-ASSEMBLY
1. Install the oil cooler tube sub-assembly with the 2 bolts.
  
  Fig 9: Locating Oil Cooler Tube Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL THROTTLE BODY ASSEMBLY . Refer to INSTALLATION - Step 1
INSTALL AIR CLEANER CASE SUB-ASSEMBLY . Refer to INSTALLATION - Step 66
INSTALL AIR CLEANER CAP SUB-ASSEMBLY . Refer to INSTALLATION - Step 2
ADD ENGINE COOLANT . Refer to REPLACEMENT - Step 4
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
INSPECT FOR COOLANT LEAK . Refer to ON-VEHICLE INSPECTION - Step 1
INSPECT FOR FUEL LEAK
REMOVE NO. 2 ENGINE UNDER COVER
INSTALL REAR ENGINE UNDER COVER RH
INSTALL ENGINE UNDER COVER
INSTALL NO. 1 AIR CLEANER INLET . Refer to INSTALLATION - Step 91
INSTALL ENGINE ROOM SIDE COVER RH . Refer to INSTALLATION - Step 92
INSTALL ENGINE ROOM SIDE COVER LH . Refer to INSTALLATION - Step 93
INSTALL COOL AIR INTAKE DUCT SEAL . Refer to INSTALLATION - Step 94
INSTALL V-BANK COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 95