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Intake Manifold: Installation

  1. INSTALL INTAKE MANIFOLD SUB-ASSEMBLY UPPER 
    1. Set 2 new gaskets on the cylinder head.

      HINT:

      Make sure the white paint marks are facing upward.

      Fig 1: Identifying Cylinder Head Gaskets With White Paint Mark
      G05287396Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the intake manifold to the gasket and cylinder head with the 6 bolts and 4 nuts.

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

    3. Connect the 8 injector connectors.
  2. CONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY 
    1. Connect the No. 2 fuel pipe (see FUEL SYSTEM ).
    Fig 2: Locating Injector Connectors
    G05289270Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. CONNECT ENGINE WIRE 
    1. Install the wire protector (LH side) with the 3 bolts.
    2. Install the 2 wire clamps on the engine wire (RH side) to the brackets on the RH delivery pipe.
    3. Install the engine wire protector (rear side) to the rear water bypass joint and RH cylinder head with the 2 bolts.
  4. INSTALL NO. 3 V-BANK COVER BRACKET 
    1. Install the bracket to the manifold with the bolt, as shown in E in the illustration below.

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

    2. Connect the connector as shown in E in the illustration below.
  5. INSTALL NO. 2 V-BANK COVER BRACKET 
    1. Install the bracket to the manifold with the bolt, as shown in D in the illustration below.

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

  6. INSTALL VACUUM SWITCHING VALVE ASSEMBLY (for EVAP) 
    1. Install the bracket of the VSV to the manifold with the bolt, as shown in C in the illustration below.

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

    2. Connect the vacuum hose to the VSV, as shown in C in the illustration below.
    3. Connect the connector to the VSV, as shown in C in the illustration below.
  7. INSTALL V-BANK COVER BRACKET 
    1. Install the bracket to the manifold with the bolt, as shown in the illustration B below.

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

    Fig 3: Locating Engine Wire Protector To Rear Water By-Pass Joint And RH Cylinder Head With Bolts
    G05287398Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL NO. 4 V-BANK COVER BRACKET 
    1. Install the bracket to the manifold with the 2 nuts, as shown in the illustration A below.

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

    Fig 4: Locating Bracket To Manifold With Nuts
    G05287381Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL THROTTLE BODY ASSEMBLY (See  MASS AIR FLOW METER  ) 
  10. INSTALL INTAKE AIR CONNECTOR PIPE (See  MASS AIR FLOW METER  ) 
  11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  12. CHECK FOR FUEL LEAKS 
    1. Check for fuel leaks (see FUEL SYSTEM ).
  13. ADD ENGINE COOLANT (See  COOLANT  ) 
  14. CHECK FOR COOLANT LEAKS 
    1. Check for engine coolant leaks (see COOLING SYSTEM ).
  15. INSTALL V-BANK COVER SUB-ASSEMBLY
    1. Install the cover with the 2 nuts.

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

  16. INSTALL ENGINE ROOM SIDE COVER LH (See  INSPECTION PROCEDURE  ) 
  17. INSTALL ENGINE ROOM SIDE COVER RH (See  INSPECTION PROCEDURE  ) 
  18. INSTALL AIR CLEANER INLET 
    1. Install the inlet with the bolt.

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

  19. INSTALL COOL AIR INTAKE DUCT SEAL (See  INSTALLATION  ) 
  20. PERFORM INITIALIZATION 
    1. Perform initialization (see INITIALIZATION ).
      NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
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