Intake Manifold: Installation

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

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

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

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

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

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) 

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

(See PRECAUTION )