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Intake Manifold: Installation

  1. INSTALL INTAKE MANIFOLD 
    1. Install a new gasket onto the intake manifold.
    2. Install the intake manifold and intake manifold stay with the 4 bolts and 2 nuts.

      Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) 

      Fig 1: Locating Intake Manifold Bolts
      G05399592Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the ventilation hose.
      Fig 2: Locating Ventilation Hose
      G05398785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the 4 wire harness clamps.
      5. Fig 3: Locating Wire Harness Clamps
      G05398784Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL THROTTLE BODY ASSEMBLY  (See INSTALLATION )
  3. INSTALL TRANSMISSION OIL LEVEL GAUGE SUB-ASSEMBLY 
    1. Install the transmission oil level gauge sub-assembly with the bolt.

      Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

      Fig 4: Locating Transmission Oil Level Gauge Sub-Assembly With Bolt
      G05399589Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the breather hose.
    3. Install the transmission oil level dipstick.
  4. INSTALL OIL COOLER TUBE 
    1. Install the oil cooler tube clamp.
      1. Provisionally install the outlet No. 1 oil cooler tube into the oil cooler tube union.
      2. Provisionally install the inlet No. 1 oil cooler tube into the oil cooler tube union.
      3. Install the No. 2 oil cooler tube clamp onto the transmission oil filler tube sub-assembly with the bolt.
        Fig 5: Locating Oil Cooler Tube Clamp
        G04831218Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

    2. Using a union nut wrench, install the outlet No. 1 oil cooler tube while holding the oil cooler tube union with a spanner.

      Torque: without union nut wrench 

      34 N*m (347 kgf*cm, 25 ft.*lbf) 

      Torque: with union nut wrench 

      32 N*m (327 kgf*cm, 24 ft.*lbf) 

      NOTE:
      • This torque value can be obtained by using a torque wrench with a fulcrum length of 345 mm (13.58 in.) and a union nut wrench with a fulcrum length of 30 mm (1.18 in.).
        Fig 6: Installing Outlet No. 1 Oil Cooler Tube
        G05399598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • This torque value is effective when the union nut wrench is parallel to the torque wrench.
    3. Using a union nut wrench, install the inlet No. 1 oil cooler tube while holding the oil cooler tube union with a spanner.

      Torque: without union nut wrench 

      34 N*m (347 kgf*cm, 25 ft.*lbf) 

      Torque: with union nut wrench 

      32 N*m (327 kgf*cm, 24 ft.*lbf) 

      NOTE:
      • This torque value can be obtained by using a torque wrench with a fulcrum length of 345 mm (13.58 in.) and a union nut wrench with a fulcrum length of 30 mm (1.18 in.).
        Fig 7: Installing Inlet No. 1 Oil Cooler Tube
        G05399599Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • This torque value is effective when the union nut wrench is parallel to the torque wrench.
  5. INSTALL ENGINE OIL LEVEL DIPSTICK 
  6. INSTALL STARTER ASSEMBLY  (See INSTALLATION )
  7. INSTALL INJECTOR VIBRATION INSULATOR  (See INSTALLATION )
  8. INSTALL NO. 1 DELIVERY PIPE SPACER  (See INSTALLATION )
  9. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY  (See INSTALLATION )
  10. CONNECT FUEL TUBE SUB-ASSEMBLY  (See INSTALLATION )
  11. INSTALL FUEL PIPE CLAMP  (See INSTALLATION )
  12. CONNECT VACUUM HOSE  (See INSTALLATION )
  13. CONNECT NO. 1 FUEL VAPOR FEED HOSE  (See INSTALLATION )
  14. INSTALL HARNESS BRACKET  (See INSTALLATION )
  15. INSTALL ENGINE WIRE HARNESS  (See INSTALLATION )
  16. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE  (See INSTALLATION )
  17. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 

    Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

  18. ADD ENGINE COOLANT  (See REPLACEMENT )
  19. INSPECT FOR COOLANT LEAK  (See ON-VEHICLE INSPECTION )
  20. INSPECT FOR FUEL LEAK 

    (See PRECAUTION )

  21. INSTALL NO. 2 CYLINDER HEAD COVER  (See INSTALLATION )
  22. INSTALL ENGINE UNDER COVER RH 

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

  23. INSTALL ENGINE UNDER COVER LH 

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

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