Intake Manifold To Head Gasket No. 1: Replacement

DRAIN ENGINE COOLANT (See ENGINE COOLANT )
DISCHARGE FUEL SYSTEM PRESSURE
DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
REMOVE V-BANK COVER
1. Remove the 2 nuts and V-bank cover.
REMOVE INTAKE AIR CONNECTOR PIPE
1. Disconnect the air hose and ventilation hose No. 1.
2. Loosen the 2 clamps. Then remove the bolt and intake air connector pipe.
REMOVE THROTTLE BODY ASSY (See REPLACEMENT )
REMOVE V-BANK COVER BRACKET NO. 1
1. Remove the bolt and cover bracket.
REMOVE V-BANK COVER BRACKET NO. 2
1. Remove the bolt and cover bracket.
REMOVE V-BANK COVER BRACKET NO. 3
1. Remove the bolt and cover bracket.
REMOVE V-BANK COVER BRACKET NO. 4
1. Remove the 2 nuts and cover bracket.
REMOVE VACUUM SWITCHING VALVE ASSY
1. Disconnect the VSV connector.
2. Disconnect the 2 hoses from the VSV.
3. Remove the bolt and VSV.
DISCONNECT FUEL PIPE SUB-ASSY NO. 2
1. Using SST, disconnect the fuel pipe.
  SST 09023-38401
  
  Fig 1: Disconnecting Fuel Pipe Sub-Assy No. 2
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INTAKE MANIFOLD ASSY
1. Remove the installation bolts and the water by-pass pipe No. 1 and No. 2.
2. Disconnect the vacuum hose of the brake booster.
3. Disconnect the air hose of the power steering.
4. Disconnect the ventilation hose.
5. Disconnect the 8 injector connectors.
6. Remove the 6 bolts, 4 nuts and intake manifold.
REMOVE INTAKE MANIFOLD TO HEAD GASKET NO. 1
INSTALL INTAKE MANIFOLD TO HEAD GASKET NO. 1
1. Install 2 new gaskets to the cylinder head.
  HINT:
  
  The side of the gasket with white paint should point outward.
  
  Fig 2: Installing Intake Manifold To Head Gasket No. 1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INTAKE MANIFOLD ASSY
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.
6. Install the water by-pass pipe No. 1 and No. 2 with the bolt.
INSTALL FUEL PIPE SUB-ASSY NO. 2
1. Using SST, install the fuel pipe.
  SST 09023-38401
  
  Torque:
  - 35 N.m (357 kgf.cm, 26 ft.lbf)
  - 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 Fuel Pipe Sub-Assy No. 2
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VACUUM SWITCHING VALVE ASSY
1. Install the VSV with the bolt.
  Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf)
INSTALL V-BANK COVER BRACKET NO. 4
1. Install the cover bracket with the 2 nuts.
  Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf)
INSTALL V-BANK COVER BRACKET NO. 3
1. Install the cover bracket with the bolt.
  Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf)
INSTALL V-BANK COVER BRACKET NO. 2
1. Install the cover bracket with the bolt.
  Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf)
INSTALL V-BANK COVER BRACKET NO. 1
1. Install the cover bracket with the bolt.
  Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf)
INSTALL THROTTLE BODY ASSY (See REPLACEMENT )
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 No. 1 together.
CHECK FOR FUEL LEAKS (See PRECAUTION )
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)
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
PERFORM INITIALIZATION (See INITIALIZATION )
NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
ADD ENGINE COOLANT (See ENGINE COOLANT )
CHECK FOR ENGINE COOLANT LEAKS (See ENGINE COOLANT )