Installation

1GR-FE INTAKE: INTAKE MANIFOLD: INSTALLATION

1. INSTALL INTAKE MANIFOLD

(a) Set a new gasket on each cylinder head.





NOTICE:
* Align the port holes of the gasket and cylinder head.
* Be careful of the installation direction.

(b) Set the intake manifold on the cylinder heads.

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





Text in Illustration





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

HINT
Tighten the inner installation bolts of the intake manifold before tightening the outer bolts.

2. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY Installation

3. CONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY Installation

4. CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY Installation

5. INSTALL REAR CYLINDER HEAD COVER Installation

6. INSTALL INTAKE AIR SURGE TANK

(a) Install a new gasket to the intake air surge tank.

(b) Install the intake air surge tank in the order shown in the illustration.

(1) Using an 8 mm socket hexagon wrench, temporarily tighten the 4 bolts to the intake air surge tank.





(2) Temporarily tighten the 2 nuts to the intake air surge tank.

Text in Illustration





(3) Tighten the 4 bolts and 2 nuts.

Torque : 28 Nm (286 kgf-cm, 21 ft-lbf)

(c) Install the No. 2 surge tank stay with the 2 bolts in the order shown in the illustration.





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

(d) Install the No. 1 surge tank stay with the 2 bolts in the order shown in the illustration.





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

(e) Engage the wire harness clamp.

(f) Install the throttle body bracket with the 2 bolts in the order shown in the illustration.





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

(g) Connect the No. 1 ventilation hose.





Text in Illustration





(h) Connect the No. 1 vacuum switching valve connector.





Text in Illustration





(i) Connect the No. 1 fuel feed hose.

HINT
Connect the hose so that the direction of the hose clamp is as indicated in the illustration.

(j) Connect the throttle body connector.

(k) Connect the No. 4 water by-pass hose.





Text in Illustration





HINT
Connect the hose so that the direction of the hose clamp is as indicated in the illustration.

(l) Connect the No. 5 water by-pass hose.

HINT
Connect the hose so that the direction of the hose clamp is as indicated in the illustration.

(m) Connect the 2 heater hose clamps.

7. INSTALL AIR CLEANER HOSE ASSEMBLY

(a) Install the air cleaner hose assembly with the 2 hose clamps.





Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)

Text in Illustration





(b) Install the bolt.

Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)

(c) Connect the vacuum hose and ventilation hose.

HINT
Connect the hose so that the direction of the hose clamp is as indicated in the illustration.

(d) Engage the wire harness clamp.

8. ADD ENGINE COOLANT Service and Repair

9. INSPECT FOR COOLANT LEAK Testing and Inspection

10. INSPECT FOR FUEL LEAK Fuel System

11. INSTALL V-BANK COVER

(a) Engage the 2 V-bank cover hooks to the bracket.

(b) Align the 2 V-bank cover grommets with the 2 pins and press down on the V-bank cover to engage the pins.