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Intake Manifold: Installation

  1. INSTALL INTAKE MANIFOLD 
    NOTE: DO NOT apply oil to the bolts listed below:
    TIGHTENING TORQUE

    Tightening Parts
    Intake Manifold and Cylinder Head Sub-assembly RH
    Intake Manifold and Cylinder Head Sub-assembly LH
    1. Set 2 new gaskets on each cylinder head.
      NOTE:
      • Align the port holes of the gaskets and cylinder head.
      • Make sure that the gaskets are installed in the correct direction.
    2. Set the intake manifold on the cylinder heads.
    3. Install the intake manifold with the 6 bolts and 4 nuts in the order shown in the illustration.

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

  2. INSTALL NO. 2 ENGINE MOUNTING STAY RH 
    1. Install the No. 2 engine mounting stay RH.
      Fig 1: Locating No. 2 Engine Mounting Stay RH Bolts And Nuts
      G05414997Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the bolt [A].

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

    3. Install the 2 nuts [B].

      Torque: 23 N*m (234 kgf*cm, 17 ft.*lbf) 

    4. Install the bolt [C].

      Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) 

    5. Install the 3 bolts [D].

      Torque: 8.3 N*m (84 kgf*cm, 73 in.*lbf) 

    Fig 2: Locating Nuts And Bolts
    G05414998Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY 
    1. Install 6 new insulators to the intake manifold.
      Fig 3: Locating Injector Vibration Insulators And Intake Manifold
      G05138184Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place the fuel delivery pipe which has the 6 fuel injectors installed to it in position on the intake manifold.
      NOTE: Be careful not to drop the fuel injectors when installing the fuel delivery pipe.
    3. Temporarily install the 5 bolts which are used to hold the fuel delivery pipe to the intake manifold.
      Fig 4: Identifying Fuel Delivery Pipe And Fuel Injectors
      G05415000Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: After installing the fuel injectors, check that they turn smoothly. If not, reinstall the injectors with new O-rings.
    4. Tighten the 5 bolts which are used to hold the fuel delivery pipe to the intake manifold.

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

      Fig 5: Locating Bolts And Fuel Delivery Pipe Sub-Assembly
      G04975009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the 6 fuel injector connectors.
    Fig 6: Identifying Fuel Injector Connectors
    G04975008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. CONNECT FUEL MAIN TUBE 
    1. Push in the tube connector onto the pipe until the tube connector makes a "click" sound.
      NOTE:
      • Before connecting the tube, make sure that it is not damaged. Make sure that there is no dirt present on the connecting surfaces.
      • After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
      Fig 7: Locating Fuel Tube Sub-Assembly
      G05138197Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the No. 2 fuel pipe clamp.
  5. TEMPORARILY INSTALL NO. 1 SURGE TANK STAY 
    NOTE: DO NOT apply oil to the bolts listed below:
    TIGHTENING TORQUE

    Tightening Parts
    No. 1 Surge Tank Stay and Intake Air Surge Tank Assembly
    No. 1 Surge Tank Stay and Cylinder Head Cover RH
    1. Temporarily install the intake air surge tank assembly with 3 new gaskets on the intake manifold
      NOTE: Do not allow the gaskets to slip out of place during installation.
    2. Temporarily install the No. 1 surge tank stay with the 2 bolts.
    Fig 8: Locating No. 1 Surge Tank Stay And Bolts
    G05415004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. TEMPORARILY INSTALL THROTTLE BODY BRACKET 
    NOTE: DO NOT apply oil to the bolts listed below:
    TIGHTENING TORQUE

    Tightening Parts
    Throttle body bracket and Intake Air Surge Tank Assembly
    Throttle body bracket and Cylinder Head Cover RH
    1. Temporarily install the throttle body bracket with the 2 bolts.
  7. INSTALL INTAKE AIR SURGE TANK ASSEMBLY 
    NOTE: DO NOT apply oil to the bolts listed below:
    TIGHTENING TORQUE

    Tightening Parts
    Intake Manifold and Intake Air Surge Tank Assembly
    Fig 9: Locating Bolts And Throttle Body Bracket
    G05415005Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the surge tank with the 4 bolts and 2 nuts in the order shown in the illustration.

      Torque: Nut 

      16 N*m (163 kgf*cm, 12 ft.*lbf) 

      Bolt 

      18 N*m (183 kgf*cm, 13 ft.*lbf) 

      HINT:

      Use a 5 mm hexagon socket wrench to tighten the 4 bolts.

      Fig 10: Locating Surge Tank Bolts
      G05415006Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the 2 water by-pass hoses to the throttle with motor body assembly.
      Fig 11: Identifying Water By-Pass Hoses
      G05414988Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the connector.
    4. Install the clamp and connect the throttle with motor body assembly connector.
      Fig 12: Identifying Throttle Body Connector And Clamp
      G05414987Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the 4 hoses.

      HINT:

      • E: vapor feed hose
      • F: union to check valve hose
      • G: No. 1 ventilation hose
      • H: vacuum hose
      Fig 13: Locating Hoses
      G05415009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. FULLY TIGHTEN NO. 1 SURGE TANK STAY 
    NOTE: DO NOT apply oil to the bolts listed below:
    TIGHTENING TORQUE

    Tightening Parts
    No. 1 Surge Tank Stay and Intake Air Surge Tank Assembly
    No. 1 Surge Tank Stay and Cylinder Head Cover RH
    1. Fully tighten the 2 bolts in the order shown in the illustration.

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

  9. FULLY TIGHTEN THROTTLE BODY BRACKET 
    NOTE: DO NOT apply oil to the bolts listed below:
    TIGHTENING TORQUE

    Tightening Parts
    Throttle body bracket and Intake Air Surge Tank Assembly
    Throttle body bracket and Cylinder Head Cover RH
    Fig 14: Locating No. 1 Surge Tank Stay And Bolts
    G05415010Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Fully tighten the 2 bolts in the order shown in the illustration.

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

    Fig 15: Locating No. 1 Surge Tank Stay And Bolts
    G05415011Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. CONNECT ENGINE ROOM MAIN WIRE 
    1. Connect the 5 harness clamps.
  11. INSTALL AIR CLEANER CAP SUB-ASSEMBLY  (See INTAKE MANIFOLD )
  12. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY  (See INSTALLATION )
  13. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY  (See INSTALLATION )
    Fig 16: Identifying Harness Clamps
    G05414983Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  (See INSTALLATION )
  15. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See INSTALLATION )
  16. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See INSTALLATION )
  17. ADD ENGINE COOLANT  (See REPLACEMENT )
  18. INSPECT FOR ENGINE COOLANT LEAK  (See COOLING SYSTEM )
  19. INSPECT FOR FUEL LEAK  (See ON-VEHICLE INSPECTION )
  20. INSTALL V-BANK COVER SUB-ASSEMBLY  (See INSTALLATION )
  21. INSTALL NO. 1 ENGINE UNDER COVER  (See INSTALLATION )
  22. INSTALL ENGINE UNDER COVER ASSEMBLY  (See INSTALLATION )
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