Intake Manifold: Installation

INSTALL INTAKE MANIFOLD
1. Install 2 new gaskets to the intake manifold.
  
  Fig 1: Locating Intake Manifold Bolts And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Temporarily install the intake manifold 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: Tightening Sequence Of Intake Manifold Bolt And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the PCV hose to the intake manifold.
  NOTE: Make sure that the clip is facing as shown in the illustration.
  
  Fig 3: Position Of Installing PCV Hose Clip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PURGE VSV
1. Install the purge VSV with the bolt.
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
2. Connect the fuel vapor feed hose to the intake manifold.
3. Connect the No. 2 fuel vapor feed hose to the purge VSV.
  
  Fig 4: Locating Fuel Vapor Feed Hose And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
1. Install the water by-pass pipe to the intake manifold with the 2 bolts.
2. Connect the heater water inlet hose, heater water outlet hose, water inlet hose, and No. 3 water bypass hose to the water by-pass pipe with the 4 clamps.
  NOTE: Make sure that the No. 3 water by-pass hose clamp is facing as shown in the illustration.
  
  Fig 5: Position Of Installing No. 3 Water By-Pass Hose Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INJECTOR DRIVER
1. Install the injector driver to the intake manifold by installing the 2 bolts and 2 nuts in the order shown in the illustration.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
2. Connect the 4 wire harness connectors to the injector driver. Then move the lock lever as shown in the illustration to lock the connectors.
3. Connect the 2 clamps to the injector driver.
CONNECT ENGINE WIRE
1. for 2WD:
  1. Connect the engine wire harness connectors.
    HINT:
    
    To connect the injector driver connectors, move the lock lever to lock the connector.
  2. Connect the engine wire harness to the +B terminal of the generator assembly with the nut.
    Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
  3. Connect the 6 engine wire harness clamps.
  4. Connect the engine wire to the fusible link block assembly with the nut.
    Torque: 13 N*m (127 kgf*cm, 10 ft.*lbf)
    
    Fig 6: Installing Injector Driver
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Connect the engine wire harness ground with the bolt.
    Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
  6. Install the 4 engine wire harness clamp brackets with the 4 bolts.
    Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  7. Connect the engine wire harness with the 4 nuts.
    Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
    
    Fig 7: Locating Engine Wire Harness Clamps, Brackets With Fasteners (2WD)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. for AWD:
  1. Connect the engine wire harness connectors.
    HINT:
    
    To connect the injector driver connectors, move the lock lever to lock the connector.
  2. Connect the engine wire harness to the +B terminal of the generator assembly with the nut.
    Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
  3. Connect the 6 engine wire harness clamps.
  4. Connect the engine wire to the fusible link block assembly with the nut.
    Torque: 13 N*m (127 kgf*cm, 10 ft.*lbf)
  5. Connect the engine wire harness ground with the bolt.
    Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
  6. Install the 3 engine wire harness clamp brackets with the 3 bolts.
    Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  7. Connect the engine wire harness with the 4 nuts.
    Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
    
    Fig 8: Locating Engine Wire Harness Clamps, Brackets With Fasteners (AWD)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. Connect the wire harness bracket with the bolt.
    Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  9. Connect the cooler compressor connector.
    
    Fig 9: Locating Bolt And Wire Harness Bracket
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. Install the clamp bracket with the bolt.
    Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  11. Connect the 2 clamps and 3 ground wires with the 3 bolts.
    Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  12. Connect the 2 camshaft timing control motor connectors (for Bank 1).
  13. Connect the oil pressure sensor connector.
  14. Connect the engine coolant temperature sensor connector.
    
    Fig 10: Locating Camshaft Timing Control Motor Connectors, Bolts And Clamps
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. Connect the clamp and install the 2 clamp brackets with the 2 bolts.
    Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  16. Connect the No. 8 engine wire connector.
  17. Connect the fuel pump connector (for high pressure).
  18. Connect the 2 WT sensor connectors.
  19. Connect the 4 ignition coil connectors.
  20. Connect the camshaft timing control valve connector.
    
    Fig 11: Locating Engine Wire Connector Bolts, Clamp And Ignition Coil Connectors
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR CLEANER ASSEMBLY LH
1. Install the air cleaner case with the 2 nuts and clip.
  Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
2. Install the air cleaner filter element to the air cleaner case.
  
  Fig 12: Locating Air Cleaner Case Nuts And Clips
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the air cleaner cap with the 2 clamps.
4. Connect the MAF meter connector.
  
  Fig 13: Locating Air Cleaner Clamps And MAF Meter Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR CLEANER ASSEMBLY RH
1. Install the air cleaner case with the 2 nuts and clip.
  Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
2. Install the air cleaner filter element to the air cleaner case.
  
  Fig 14: Locating Air Cleaner Case Nuts And Clips
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the air cleaner cap with the 2 clamps.
4. Connect the MAF meter connector.
INSTALL THROTTLE BODY (See INSTALLATION )
INSTALL INTAKE AIR CONNECTOR PIPE (See INSTALLATION )
INSTALL NO. 1 AIR CLEANER INLET (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 ).
ADD ENGINE COOLANT (See REPLACEMENT )
INSPECT FOR ENGINE COOLANT LEAK (See ON-VEHICLE INSPECTION )
INSTALL ENGINE ROOM SIDE COVER RH (See INSTALLATION )
INSTALL AIR CLEANER INLET COVER (See INSTALLATION )
INSTALL V-BANK COVER SUB-ASSEMBLY (See INSTALLATION )
INSTALL NO. 2 ENGINE UNDER COVER (See INSTALLATION )
INSTALL FRONT SUSPENSION MEMBER PROTECTOR LOWER (See INSTALLATION )
INSTALL NO. 1 ENGINE UNDER COVER (See REPLACEMENT )
INSTALL COWL TOP VENTILATOR LOUVER RH (See INSTALLATION )