Intake Manifold: Installation

WARNING: This page is about a different car, the 2008 Lexus IS F. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL INTAKE AIR SURGE TANK ASSEMBLY
1. Install the union to check valve hose bracket with the bolt.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
2. Install the V-bank cover bracket sub-assembly with the bolt.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 1: Locating V-Bank Cover Bracket Sub-Assembly Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install 2 new gaskets to the intake air surge tank assembly.
4. Temporarily install the intake air surge tank assembly with the 2 nuts and 8 bolts Then tighten the 2 nuts and 8 bolts uniformly in the order shown in the illustration
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
  
  Fig 2: Locating Intake Air Surge Tank Assembly Bolts And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
1. Apply gasoline to 8 new O-ring and install one to each injector
  NOTE: Check that there is no damage or foreign objects in the groove of the injector when installing the O-ring. If an injector falls out of the delivery pipe during removal or installation, reinstall the injector to the delivery pipe using a new O-ring between the injector and delivery pipe.
2. Install the injectors with delivery pipe assembly and 4 spacers with the 4 bolts.
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
3. Install the 2 wire harnesses with the 4 bolts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 3: Locating Fuel Delivery Pipe Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 3 FUEL HOSE (See INSTALLATION )
CONNECT VACUUM HOSE ASSEMBLY (See INSTALLATION )
INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
1. Install the water by-pass pipe to the intake air surge tank assembly with the 2 bolts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
2. Connect the heater inlet water hose, heater outlet water hose, water inlet hose, water outlet hose, and water by-pass hose to the water by-pass pipe with the 5 clamps
Fig 4: Locating Water By-Pass Pipe Clamps And Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INJECTOR DRIVER
1. Install the No. 2 V-bank cover bracket sub-assembly with the bolt
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
2. Install the 2 injector drivers with the 8 nuts
  Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
3. Connect the 4 injector driver connectors to the injector driver.
HINT:

To connect the injector driver connectors, move the lock lever to lock the connector.

Fig 5: Locating Injector Driver And Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VACUUM SWITCHING VALVE ASSEMBLY
1. Connect the ventilation hose.
2. Install the vacuum switching valve assembly with the bolt.
  Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf)
3. Connect the No. 2 fuel vapor feed hose to the vacuum switching valve assembly.
4. Connect the fuel vapor feed hose to the intake air surge tank assembly.
Fig 6: Locating Vacuum Switching Valve Assembly And Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT ENGINE WIRE
1. Connect the engine wire harness connector.
HINT:

To connect the injector driver connectors, move the lock lever to lock the connector.
1. Connect the engine wire with the 4 nuts. (A)
  
  Fig 7: Locating Engine Wire Connectors And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
2. Connect the 4 connectors and 5 clamps. (B)
3. Install the ground cable with the bolt. (C)
  Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf)
4. Connect the 4 injector driver connectors. (D)
5. Install the wire harness with the nut to the relay box. (E)
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
6. Connect the 9 connectors and 3 clamps. (F)
  
  Fig 8: Locating Engine Wire Connectors And Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Install the wire harness with the nut to the +B terminal. (G)
  Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
8. Connect the generator connector and 2 clamps (H)
9. Install the oil cooler tube sub-assembly withe the bolt and nut (1)
  Torque:
  
  Bolt
  
  10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Nut
  
  7.0 N*m (71 kgf*cm, 62 in.*lbf)
10. Connect the 2 connectors and then install the nut (J)
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
11. Connect the starter connector (K)
12. Install the 2 bolts to the No. 3 exhaust manifold heat insulator. (L)
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL OIL COOLER TUBE SUB-ASSEMBLY
1. Install the oil cooler tube sub-assembly with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

Fig 9: Locating Oil Cooler Tube Sub-Assembly Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL THROTTLE BODY ASSEMBLY (See INSTALLATION )
INSTALL AIR CLEANER CASE SUB-ASSEMBLY (See INSTALLATION )
INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See INSTALLATION )
ADD ENGINE COOLANT (See REPLACEMENT )
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
INSPECT FOR COOLANT LEAK (See COOLING SYSTEM )
INSPECT FOR FUEL LEAK
(See PRECAUTION )
INSTALL NO. 2 ENGINE UNDER COVER
INSTALL REAR ENGINE UNDER COVER RH
INSTALL ENGINE UNDER COVER
INSTALL NO. 1 AIR CLEANER INLET (See INSTALLATION )
INSTALL ENGINE ROOM SIDE COVER RH (See INSTALLATION )
INSTALL ENGINE ROOM SIDE COVER LH (See INSTALLATION )
INSTALL COOL AIR INTAKE DUCT SEAL (See INSTALLATION )
INSTALL V-BANK COVER SUB-ASSEMBLY (See INSTALLATION )