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Intake Manifold: Installation

WARNING: This page is about a different car, the 2008 Toyota Tundra. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY  (See INSTALLATION )
  2. INSTALL VACUUM SWITCHING VALVE ASSEMBLY (for ACIS)  (see INSPECTION  )
  3. INSTALL PURGE VSV 
    1. Install the VSV with the bolt to the intake manifold.

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

    2. Connect the purge line hose to the intake manifold.
      3. Fig 1: Identifying Purge Line Hose From Intake Manifold
      G05152702Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL NO. 1 VENTILATION HOSE 
  5. INSTALL THROTTLE BODY ASSEMBLY 
    1. Align the protrusion of a new gasket with the groove of the intake manifold, and install the gasket.
      Fig 2: Aligning Protrusion Of Gasket With Groove Of Intake Manifold
      G05152704Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the throttle body with the nut and 3 bolts.

      Torque: 14 N*m (143 kgf*cm, 10 ft.*lbf) 

      Fig 3: Identifying Throttle Body Assembly Bolts
      G05152701Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL INTAKE MANIFOLD ASSEMBLY 
    1. Place 2 new gaskets on the intake manifold.
      2. Fig 4: Identifying Gaskets On Intake Manifold
      G05152706Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place the intake manifold on the cylinder heads.
    3. Install and uniformly tighten the 6 bolts and 4 nuts in several steps.

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

      Fig 5: Identifying Intake Manifold Bolts And Nuts
      G05152700Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the engine wire protector with the 2 bolts.

      Torque: 8.2 N*m (83 kgf*cm, 72 in.*lbf) 

      Fig 6: Identifying Engine Wire Protector And Bolts
      G05152699Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the 8 injector connectors.
    6. Connect the 2 wire clamps to the wire clamp brackets on the RH delivery pipe.
      Fig 7: Identifying Wire Clamps
      G05152698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Connect the VSV connector (for ACIS).
      Fig 8: Identifying VSV Connector
      G05152696Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Install the wire bracket to the intake manifold with the bolt.

      Torque: 8.2 N*m (83 kgf*cm, 72 in.*lbf) 

      Fig 9: Identifying Wire Bracket From Intake Manifold
      G05152697Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Connect the engine wire to the wire bracket and engine hanger.
    9. Connect the purge line hose to the purge VSV.
    10. Connect the purge VSV connector.
      Fig 10: Identifying Purge VSV Connector
      G05152695Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Connect the No. 1 ventilation hose to the ventilation valve on the LH cylinder head.
      Fig 11: Identifying No. 1 Ventilation Hose
      G05152694Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. Connect the 2 water by-pass hoses to the throttle body.
    13. Connect the throttle position sensor and control motor connector.
  7. INSTALL FUEL MAIN TUBE  (See INSTALLATION )
  8. INSTALL FUEL RETURN TUBE  (See INSTALLATION )
  9. INSTALL NO. 2 WATER BYPASS PIPE 
    1. Connect the 2 hoses to the water by-pass pipe.
      2. Fig 12: Identifying Water By-Pass Hoses From Throttle Body
      G05152693Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the No. 2 water by-pass pipe with the 2 bolts.

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

      Fig 13: Identifying No. 2 Water By-Pass Pipe Together With Water Hose
      G05152692Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the 2 water hoses.
      Fig 14: Identifying Water Hoses From No. 2 Water By-Pass Pipe
      G05152691Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL VACUUM HOSE ASSEMBLY 
    1. Connect the hose to the intake manifold.
      2. Fig 15: Identifying Vacuum Hose Assembly
      G05152690Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the vacuum hose assembly with the bolt.

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

  11. INSTALL AIR CLEANER HOSE ASSEMBLY  (see INSTALLATION  )
  12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE: Some systems need to be initialized after the cable is reconnected (see INITIALIZATION ).
  13. ADD ENGINE COOLANT  (See REPLACEMENT )
  14. INSPECT FOR COOLANT LEAK 
  15. INSPECT FOR FUEL LEAK  (See INSTALLATION )
  16. INSTALL NO. 1 ENGINE UNDER COVER  (See REPLACEMENT )
  17. INSTALL THROTTLE BODY COVER SUB-ASSEMBLY 
    1. Install the 2 throttle body cover brackets with the 2 bolts.

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

      Fig 16: Identifying Throttle Body Cover Brackets From Intake Manifold
      G05152689Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the throttle body cover with the 2 cap nuts.

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

      Fig 17: Identifying Cap Nuts And Throttle Body Cover
      G05152688Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL FRONT COWL TOP OUTER PANEL SUB-ASSEMBLY 
    1. Install the outer panel with the 7 bolts.

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

      Fig 18: Identifying Bolts On Outer Panel
      G05152567Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the 2 washer hoses.
  19. INSTALL FRONT WIPER MOTOR AND LINK 
    1. For the front wiper motor and link, refer to the following procedures (see INSTALLATION ).
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