Intake Manifold To Head Gasket No.1: Replacement

DRAIN ENGINE COOLANT
WORK FOR PREVENTING GASOLINE FROM SPILLING OUT
REMOVE V-BANK COVER
1. Remove the 2 nuts and V-bank cover.
REMOVE AIR CLEANER INLET NO.1
REMOVE INTAKE AIR CONNECTOR PIPE
1. Disconnect the air hose and ventilation hose No.1.
2. Remove the bolt, hose clamp and intake air connector pipe.
REMOVE THROTTLE BODY ASSY
1. Disconnect the connector from the throttle body.
2. Disconnect the PCV hose.
3. Disconnect the 2 water by-pass hoses.
  HINT:
  
  It is not necessary to disconnect the water by-pass hose that has both ends connected to the throttle body.
4. Remove the bolts, 2 nuts and throttle body.
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 FOR EVAP
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 main hose.
  
  Fig 1: Disconnecting Fuel Main Hose Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09023-38400
REMOVE INTAKE MANIFOLD
1. Remove the bolt and the water by-pass pipe No.1 and No.2.
2. Disconnect the vacuum hose for the brake booster.
3. Disconnect the air hose for the power steering.
4. Disconnect the ventilation hose.
5. Disconnect the injector connector.
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 white-painted area on each gasket should face up as shown in the illustration.
Fig 2: Identifying White-Painted Area On Gasket
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INTAKE MANIFOLD
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 injector connector.
3. Connect 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.
CONNECT FUEL PIPE SUB-ASSY NO.2
1. Using SST, Install the fuel main hose.
  
  Fig 3: Installing Fuel Main Hose Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09023-38400
  
  Torque: 35 N.m (355 kgf.cm, 26 in. lbf)
INSTALL VACUUM SWITCHING VALVE ASSY FOR EVAP
1. Install the VSV with the bolt.
  Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf)
INSTALL V-VANK 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
1. Install the throttle body with the 2 bolts and 2 nuts.
2. Connect the water by-pass hose.
3. Connect the PCV hose.
4. Connect the connector to the throttle body.
INSTALL INTAKE AIR CONNECTOR PIPE
1. Install the intake air connector pipe with the bolt and hose clamp.
  torque:
  
  4.0 N.m (40 kgf.cm, 35 in. lbf) for hose clamp
  
  5.0 N.m (50 kgf.cm, 44 in. lbf) for bolt
2. Connect the air hose and ventilation hose No.1 together.
INSTALL AIR CLEANER INLET NO.1
INSPECT FUEL PUMP OPERATION AND CHECK FOR FUEL LEAKS
INSTALL V-BANK COVER
1. Install the V-bank cover with the 2 nuts.
  Torque: 5.0 N.m (50 kgf.cm, 44 in. lbf)
REFILL ENGINE COOLANT
CHECK FOR ENGINE COOLANT LEAKS
1. Check for engine coolant leaks.
  If leaks are present, find the leak and repair or replace parts as necessary.