Up to 08/2009

2GR-FE INTAKE / EXHAUST: INTAKE MANIFOLD: INSTALLATION

1. INSTALL INTAKE MANIFOLD

(a) Set 2 new intake manifold to head gaskets on each cylinder head.





NOTICE:
* Align the port holes of the gaskets and cylinder head.
* Make sure that the gaskets are installed in the correct direction.
(b) Set the intake manifold on the cylinder head.

(c) Install and tighten the 6 bolts and 4 nuts uniformly in several steps.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

2. INSTALL FUEL INJECTOR ASSEMBLY Installation

3. CONNECT FUEL TUBE SUB-ASSEMBLY Installation

4. INSTALL NO. 2 ENGINE MOUNTING STAY RH Installation

5. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

NOTICE:

DO NOT apply oil to the bolts listed below:






(a) Install 3 new air surge tank to intake manifold gaskets to the intake air surge tank.

(b) Using a 5 mm hexagon socket wrench, install the intake air surge tank assembly with the 4 bolts and 2 nuts.





Bolt - Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)

Nut - Torque : 16 Nm (163 kgf-cm, 12 ft-lbf)

(c) Install the throttle body bracket and No. 1 surge tank stay with the 2 bolts.





Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

(d) Connect the connector to the intake air control valve assembly.





(e) Connect the ventilation hose and vacuum hose.





(f) Connect the 2 water by-pass hoses to the throttle body assembly.





(g) Connect the vacuum hose clamp and fuel vapor feed hose.





(h) Connect the throttle body assembly connector and wire harness clamp to the throttle body assembly.





(i) Connect the union to connector tube hose.





6. INSTALL AIR CLEANER ASSEMBLY

(a) Install the air cleaner assembly Installation.

7. INSPECT FOR FUEL LEAK

(a) Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs Testing and Inspection.