Intake Manifold: Installation

INSTALL WIRE HARNESS CLAMP BRACKET
1. Install the 2 wire harness clamp brackets with the 2 bolts.
  Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
  
  Fig 1: Locating Wire Harness Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PURGE VSV
1. Connect the purge line hose to the intake manifold.
2. Install the purge VSV to the intake manifold with the bolt.
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
  
  Fig 2: Identifying Purge VSV & Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VACUUM SWITCHING VALVE ASSEMBLY (for ACIS)
1. Install the vacuum switching valve to the intake manifold with the bolt.
  Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
2. Connect the 2 vacuum hoses to the vacuum switching valve.
  
  Fig 3: Locating Vacuum Switching Valve Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL THROTTLE BODY ASSEMBLY
1. Align the protrusion of a new gasket with the groove of the intake manifold, and install the gasket.
  
  Fig 4: Aligning Protrusion Of Gasket With Groove Of Intake Manifold
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the throttle body with the 4 bolts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 5: Locating Throttle Body Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 V-BANK COVER BRACKET SUB-ASSEMBLY
1. Install the bracket with the bolt.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 6: Locating V-Bank Cover Bracket Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL V-BANK COVER BOLT
1. Install the cover bolt to the intake manifold.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 7: Locating Intake Manifold V-Bank Cover Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 V-BANK COVER BRACKET
1. Install the bracket with the 2 bolts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 8: Locating V-Bank Cover Bracket Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VENTILATION HOSE ASSEMBLY
1. Install the ventilation hose to the intake manifold with the 2 bolts.
  Torque:
  
  for bolt A
  
  21 N*m (214 kgf*cm, 15 ft.*lbf)
  
  for bolt B
  
  10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 9: Locating Ventilation Hose Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INTAKE MANIFOLD
1. Place 2 new gaskets on the intake manifold.
2. Place the intake manifold on the cylinder head.
  
  Fig 10: Identifying Intake Manifold Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install and uniformly tighten the 8 bolts and 2 nuts in several steps.
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
  
  Fig 11: Locating Intake Manifold Nuts And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the wire bracket to the intake manifold with the bolt.
  Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
  
  Fig 12: Locating Wire Bracket Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Connect the 3 wire clamps to the 3 wire brackets.
  
  Fig 13: Locating Wire Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the No. 3 engine cover.
  
  Fig 14: Identifying No. 3 Engine Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Install the No. 1 engine cover sub-assembly.
  
  Fig 15: Identifying No. 1 Engine Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Connect the purge VSV connector.
9. Connect the purge line hose to the purge VSV.
10. Connect the vacuum switching valve connector (for ACIS).
  
  Fig 16: Locating Purge VSV Connector And Purge Line Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. Connect the No. 1 ventilation hose.
  
  Fig 17: Locating No. 1 Ventilation Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. Connect the 2 water by-pass hoses.
13. Connect the throttle body connector.
  
  Fig 18: Locating Water By-Pass Hoses And Throttle Body Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. Connect the ventilation hose to the ventilation pipe of the cylinder head cover LH and RH.
  
  Fig 19: Locating Ventilation Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR CLEANER HOSE ASSEMBLY
1. Install the air cleaner hose so that the protrusion of the air cleaner cap aligns with the groove of the hose as shown in the illustration.
2. Tighten the 2 clamps.
  Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
3. Connect the vacuum hose.
4. Connect the No. 2 ventilation hose.
ADD ENGINE COOLANT (See REPLACEMENT )
INSPECT FOR COOLANT LEAK (See COOLING SYSTEM )
INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY (See INSTALLATION )
INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH (See INSTALLATION )
INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH (See INSTALLATION )

Fig 20: Aligning Protrusion Of Air Cleaner Cap With Groove Of Hose
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
1. Install the cowl top ventilator louver (See INSTALLATION ).
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
CHECK THROTTLE BODY ASSEMBLY (See ON-VEHICLE INSPECTION )
INSTALL V-BANK COVER SUB-ASSEMBLY (See INSTALLATION )
INSTALL UPPER RADIATOR SUPPORT SEAL (See INSTALLATION )
INSTALL ENGINE ROOM SIDE COVER LH (See INSTALLATION )
INSTALL ENGINE ROOM SIDE COVER RH (See INSTALLATION )