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Intake Manifold: Installation: Installation

WARNING: This page is about a different car, the 2012 Lexus GX 460. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL THROTTLE BODY ASSEMBLY 
    1. Align the protrusion of a new gasket with the groove of the intake manifold and install the gasket.
      Fig 1: Identifying Throttle Body Gasket
      GTY273127Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Groove
      *2 Protrusion
    2. Install the throttle body with the 4 bolts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  2. INSTALL MANIFOLD ABSOLUTE PRESSURE SENSOR  . Refer to INSTALLATION - Step 1
  3. 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) 

  4. 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.
  5. INSTALL STUD BOLT 
    1. Using an E5 "TORX" socket wrench, install the 2 stud bolts to the intake manifold.

      Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

  6. INSTALL V-BANK COVER PIN 
    1. Install the V-bank cover pin to the intake manifold.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  7. INSTALL V-BANK COVER BRACKET 
    1. Install the V-bank cover bracket to the intake manifold with the 2 bolts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  8. INSTALL FUEL TUBE SUB-ASSEMBLY 
    1. Install the 2 wire harness brackets to the intake manifold with the 2 bolts.

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

    2. Install the fuel tube to the intake manifold with the bolt.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  9. INSTALL INTAKE MANIFOLD 
    1. Place 2 new gaskets on the intake manifold.
      Fig 2: Intake Manifold Gasket Locations
      GTY167177Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place the intake manifold on the cylinder head.
    3. Install and uniformly tighten the 8 bolts and 2 nuts in several steps.

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

    4. Connect the fuel tube to the No. 2 fuel delivery pipe. Refer to PRECAUTION .
    5. Connect the fuel tube to the fuel delivery pipe. Refer to PRECAUTION .
    6. Attach the 3 wire harness clamps to the 3 wire harness brackets.
      Fig 3: Identifying Wire Harness
      GTY282369Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Connect the wire harness to the wire harness bracket with the nut.

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

    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).
    11. Connect the PCV valve hose.
    12. Connect the No. 4 water by-pass hose.
    13. Connect the throttle body connector.
  10. INSTALL AIR TUBE SUB-ASSEMBLY 
    Fig 4: Identifying Air Tube Sub-Assembly, Hoses, Connector, Clamps And Bolts
    GTY280748Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    TEXT IN ILLUSTRATION

    *1 Projection *2 Paint Mark
    *a Top *b Front
    1. Temporarily install the air tube with the 5 bolts.
    2. Connect the No. 2 air injection system hose to the air switching valve LH as shown in the illustration.
    3. Connect the manifold absolute pressure sensor connector and clamp.
    4. Attach the 2 wire harness clamps.
    5. Connect the No. 1 air injection system hose to the air switching valve RH as shown in the illustration.
    6. Connect the air hose to the air pump as shown in the illustration.
    7. Tighten the 5 bolts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  11. INSTALL RADIATOR RESERVOIR ASSEMBLY  . Refer to INSTALLATION - Step 12
  12. INSTALL VENTILATION HOSE ASSEMBLY 
    1. Install the ventilation hose with the bolt.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

    2. Connect the ventilation hose to the ventilation pipe of the cylinder head cover LH and RH.
  13. CONNECT NO. 4 WATER BY-PASS PIPE 
    1. Connect the No. 4 water by-pass pipe with the 2 bolts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  14. INSTALL WATER PIPE AND HOSE SUB-ASSEMBLY (for Single Air Conditioning System)  . Refer to INSTALLATION - Step 41
  15. INSTALL WATER PIPE AND HOSE SUB-ASSEMBLY (for Dual Air Conditioning System)  . Refer to INSTALLATION - Step 42
  16. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 
    1. Install the cowl top ventilator louver. Refer to INSTALLATION .
  17. INSTALL EGR VALVE ASSEMBLY 
    1. Install the EGR valve. Refer to INSTALLATION .
  18. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

  19. CHECK FOR FUEL LEAK  . Refer to INSTALLATION - Step 18
  20. CHECK THROTTLE BODY ASSEMBLY  . Refer to INSTALLATION - Step 8
  21. INSTALL ENGINE ROOM SIDE COVER  . Refer to INSTALLATION - Step 78
  22. INSTALL ENGINE ROOM SIDE COVER LH  . Refer to INSTALLATION - Step 79
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