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Intake Manifold: Installation: Installation

WARNING: This page is about a different car, the 2013 Toyota FJ Cruiser. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL STUD BOLT 
    1. Using "Torx" socket wrench E8, install the 2 stud bolts to the intake manifold.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  2. INSTALL INTAKE MANIFOLD 
    1. Install the new No. 1 intake manifold to head gasket and No. 2 intake manifold to head gasket to the cylinder head sub-assembly.
      Fig 1: Installing Intake Manifold To Head Gaskets
      GTY363415Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 No. 1 Intake Manifold To Head Gasket
      *2 No. 2 Intake Manifold To Head Gasket
      *a Bank 2 Identification Mark
      Front of Vehicle
      NOTE:
      • When installing the No. 1 intake manifold to head gasket and No. 2 intake manifold to head gasket, pay attention to the Bank 1 and Bank 2 sides.
      • Align the port holes of the gasket and cylinder head sub-assembly.
    2. Temporarily install the intake manifold to the cylinder head sub-assembly with the 4 nuts and 6 bolts.
    3. Install and uniformly tighten the 4 nuts and 6 bolts in several steps in the sequence shown in the illustration.
      Fig 2: Installing Intake Manifold To The Cylinder Head Sub-Assembly Nuts And Bolts In Sequence
      GTY373117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

    4. Install the wire harness clamp bracket to the intake manifold with the bolt.

      Torque: 8.0 N*m (82 kgf*cm, 70 in.*lbf) 

  3. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY  . Refer to INSTALLATION - Step 2
  4. CONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY  . Refer to INSTALLATION - Step 3
  5. CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY  . Refer to INSTALLATION - Step 4
  6. INSTALL REAR CYLINDER HEAD COVER  . Refer to INSTALLATION - Step 5
  7. INSTALL INTAKE AIR SURGE TANK 
    1. Install a new air surge tank to intake manifold gasket to the intake air surge tank.
      Fig 3: Installing Intake Manifold To Intake Air Surge Tank Gasket
      GTY372579Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using an 8 mm socket hexagon wrench, temporarily install the intake air surge tank to the intake manifold with the 4 bolts and 2 nuts.
    3. Using an 8 mm socket hexagon wrench, install and uniformly tighten the 4 bolts and 2 nuts in several steps in the sequence shown in the illustration.
      Fig 4: Installing Intake Air Surge Tank To The Intake Manifold And Fasteners In Sequence
      GTY365067Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) 

    4. Install the throttle body bracket to the intake air surge tank with the 2 bolts in the order shown in the illustration.
      Fig 5: Installing Throttle Body Bracket To Intake Air Surge Tank And Bolts In Sequence
      GTY373211Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

    5. Install the No. 1 surge tank stay to the intake air surge tank with the 2 bolts in the order shown in the illustration.
      Fig 6: Installing No. 1 Surge Tank Stay To Intake Air Surge Tank And Bolts In Sequence
      GTY371871Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

    6. Engage the clamp and connect the wire harness to the No. 1 surge tank stay.
    7. Install the No. 2 surge tank stay to the intake air surge tank with the 2 bolts in the order shown in the illustration.
      Fig 7: Installing No. 2 Surge Tank Stay To Intake Air Surge Tank And Bolts In Sequence
      GTY381125Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

    8. Connect the wire harness clamp bracket to the No. 2 surge tank stay with the bolt.

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

    9. Connect the No. 1 ventilation hose to the intake air surge tank with the hose clip.
      Fig 8: Connecting No. 1 Ventilation Hose To Intake Air Surge Tank
      GTY370463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a View A
      *b Hose Paint Mark
      *c Front of Vehicle

      HINT: 

      Make sure the No. 1 ventilation hose and hose clip are facing the directions shown in the illustration.

    10. Connect the No. 1 fuel vapor feed hose to the vacuum switching valve with the hose clip.
      Fig 9: Connecting No. 1 Fuel Vapor Feed Hose To Vacuum Switching Valve
      GTY373283Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a View A
      *b Hose Paint Mark
      *c Upper of Vehicle

      HINT: 

      Make sure the No. 1 fuel vapor feed hose and hose clip are facing the directions shown in the illustration.

    11. Connect the No. 1 vacuum switching valve connector.
    12. Connect the 2 clamps of the heater water hose to the intake air surge tank.
    13. Connect the No. 4 water by-pass hose and No. 5 water by-pass hose to the water inlet housing with the 2 clips.
      Fig 10: Connecting No. 4 Water By-Pass Hose And No. 5 Water By-Pass Hose To Water Inlet Housing
      GTY367386Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a View A
      *b Hose Paint Mark
      *c Front of Vehicle

      HINT: 

      Make sure the No. 4 water by-pass hose, the No. 5 water by-pass hose and the 2 hose clips are facing the directions shown in the illustration.

    14. Connect the throttle with motor body assembly connector.
  8. INSTALL AIR HOSE ASSEMBLY (w/ Secondary Air Injection System) 
    1. Install the air hose assembly to the No. 2 emission control valve set with the hose clip.
      Fig 11: Installing Air Hose Assembly To No. 2 Emission Control Valve Set
      GTY363650Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a View A
      *b Hose Paint Mark
      *c Upper of Vehicle
      *d Protrusion of No. 2 Emission Control Valve Set

      HINT: 

      • Align the paint mark of the air hose assembly with the protrusion of the No. 2 emission control valve set as shown in the illustration.
      • Make sure the hose clip is facing in the direction shown in the illustration.
    2. Connect the air hose assembly to the timing chain cover sub-assembly and No. 1 surge tank stay with the 2 bolts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

    3. Connect the air hose assembly to the No. 1 emission control valve set with the hose clip.
      Fig 12: Connecting Air Hose Assembly To No. 1 Emission Control Valve Set With Hose Clip
      GTY373343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a View A
      *b Hose Paint Mark
      *c Upper of Vehicle
      *d Protrusion of No. 1 Emission Control Valve Set

      HINT: 

      • Align the paint mark of the air hose assembly with the protrusion of the No. 1 emission control valve set as shown in the illustration.
      • Make sure the hose clip is facing in the direction shown in the illustration.
    4. Connect the air hose assembly to the timing chain cover sub-assembly with the bolt.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  9. CONNECT NO. 1 AIR INJECTION SYSTEM HOSE (w/ Secondary Air Injection System) 
    1. Connect the No. 1 air injection system hose to the air hose assembly with the hose clip.
      Fig 13: Connecting No. 1 Air Injection System Hose (W/ Secondary Air Injection System)
      GTY368189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a View A
      *b Hose Paint Mark
      *c Upper of Vehicle
      *d Protrusion of Air Hose Assembly

      HINT: 

      • Align the paint mark of the No. 1 air injection system hose with the protrusion of the air hose assembly as shown in the illustration.
      • Make sure the hose clip is facing in the direction shown in the illustration.
  10. INSTALL AIR CLEANER HOSE ASSEMBLY 
    1. Install the air cleaner hose assembly to the air cleaner cap sub-assembly and intake air surge tank with the 2 hose clamps.
      Fig 14: Installing Air Cleaner Hose Assembly
      GTY364515Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a View A
      *b View B
      *c Hose Paint Mark
      *d Upper of Vehicle
      *e Protrusion of Air Cleaner Cap Sub-assembly
      *f Protrusion of Intake Air Surge Tank
      *g Indentation of Air Hose Assembly

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

      HINT: 

      • Align the protrusions of the air cleaner cap sub-assembly and the intake air surge tank with the indentation of the air hose assembly.
      • Make sure the 2 hose clamps are facing in the directions shown in the illustration.
    2. Connect the air cleaner hose assembly to the resonator bracket with the bolt.

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

    3. Engage the clamp and connect the wire harness to the air cleaner hose assembly.
    4. Connect the vacuum hose to the air cleaner hose assembly.
    5. Connect the ventilation hose to the air cleaner hose assembly with the hose clip.

      HINT: 

      Make sure the ventilation hose and hose clip are facing the directions shown in the illustration.

  11. ADD ENGINE COOLANT  . Refer to REPLACEMENT - Step 2
  12. INSPECT FOR COOLANT LEAK  . Refer to ON-VEHICLE INSPECTION - Step 1
  13. INSPECT FOR FUEL LEAK  . Refer to ON-VEHICLE INSPECTION - Step 1
  14. INSTALL V-BANK COVER 
    1. Engage the 2 hooks and install the V-bank cover to the No. 1 V-bank cover 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.
  15. INSPECT INTAKE SYSTEM 

    Refer to ON-VEHICLE INSPECTION - Step 1

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