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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 INTAKE MANIFOLD SUB-ASSEMBLY 
    1. Set a new gasket on each cylinder head.
      NOTE:
      • Align the port holes of the gasket and cylinder head.
      • Be careful of the installation direction.
        • Fig 1: Identifying Intake Manifold Gasket
        G04962228Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Set the intake manifold on the cylinder heads.
    3. Install and uniformly tighten the 10 bolts in several passes.

      Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) 

      HINT:

      Tighten the inner installation bolts of the intake manifold before tightening the outer bolts.

      Fig 2: Identifying Intake Manifold Bolts
      G05152580Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY  (See INSTALLATION )
  3. INSTALL INTAKE AIR SURGE TANK 
    1. Install a new gasket to the intake air surge tank.
    2. Using an 8 mm hexagon wrench, install the intake air surge tank with the 4 bolts and 2 nuts.

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

      Fig 3: Identifying Intake Air Surge Tank With Bolts And Nuts
      G05152579Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the No. 2 surge tank stay with the 2 bolts.

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

    4. Install the No. 1 surge tank stay with the 2 bolts.

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

      Fig 4: Identifying No. 1 And 2 Surge Tank Stay With Bolts
      G05152578Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the oil baffle plate with the bolt.

      Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

      Fig 5: Identifying Bolts On Oil Baffle Plate
      G05152577Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Attach the wire harness clamp.
    7. Install the throttle body bracket with the 2 bolts.

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

      Fig 6: Identifying Throttle Body Bracket Bolts
      G05152576Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Connect the vacuum switching valve (for ACIS) connector.
      9. Fig 7: Identifying Vacuum Switching Valve Connector
      G05152575Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Attach the 2 wire harness clamps.
    10. Connect the No. 1 ventilation hose.
      Fig 8: Identifying No. 1 Ventilation Hose
      G05152574Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Connect the union to check valve hose.
    12. Connect the purge VSV connector.
    13. Connect the purge line hose.

      HINT:

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

      Fig 9: Identifying Purge Line Hose
      G05152573Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    14. Connect the No. 4 water by-pass hose.
    15. Connect the No. 5 water by-pass hose.
    16. Connect the throttle position sensor and throttle control motor connector.
      Fig 10: Identifying Throttle Control Motor Connector
      G05152590Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL AIR CLEANER ASSEMBLY WITH ELEMENT 
    1. Install the air cleaner with element with the 2 bolts.

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

    2. Tighten the hose clamp.

      HINT:

      Tighten the hose clamp until it reaches the specified protrusion height labeled A shown in the illustration.

      Standard protrusion height: Below 0.5 mm (0.0197 in.) 

      Fig 11: Identifying Hose Clamp
      G05152591Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the MAF meter connector.
      4. Fig 12: Identifying MAF Meter Connector
      G05150494Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Attach the 2 wire harness clamps.
    5. Connect the vacuum hose.
    6. Attach the hose clamp.
    7. Connect the No. 2 ventilation hose.
      8. Fig 13: Identifying No. 2 Ventilation Hose
      G05150493Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL NO. 2 AIR CLEANER HOSE  (see INSTALLATION  )
  6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE: Some systems need to be initialized after the cable is reconnected (see INITIALIZATION ).
  7. ADD ENGINE COOLANT  (See REPLACEMENT )
  8. INSPECT FOR COOLANT LEAK  (See ON-VEHICLE INSPECTION )
  9. INSPECT FOR FUEL LEAK  (See ON-VEHICLE INSPECTION )
  10. INSTALL V-BANK COVER 
    1. Install the V-bank cover with the 2 nuts.

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

      Fig 14: Identifying V-Bank Cover With Nuts
      G05152594Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL FRONT COWL TOP OUTER PANEL SUB-ASSEMBLY 
    1. Install the front cowl top outer panel with the 7 bolts.

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

      Fig 15: Identifying Front Cowl Top Outer Panel With Bolts
      G05152567Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the 2 washer hoses.
  12. INSTALL FRONT WIPER MOTOR AND LINK ASSEMBLY 
    1. Install the front wiper motor and link (see INSTALLATION ).
  13. INSTALL NO. 1 ENGINE UNDER COVER  (See INSTALLATION )
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