Intake Manifold Installation

Temporarily install a new gasket and the manifold with the 2 nuts and 4 bolts.

Tighten the 2 nuts and 4 bolts in the order shown in the illustration.

Torque:

29 N*m{296 kgf*cm, 21 ft.*lbf}

Connect the vacuum hose.

Connect the VSV connector.

Temporarily install the leakage pipe with the 3 bolts.

Temporarily install a new gasket and the check valve.

Fully tighten the 3 bolts and check valve.

Torque:

21 N*m{214 kgf*cm, 16 ft.*lbf} for check valve

13 N*m{133 kgf*cm, 10 ft.*lbf} for bolt

Connect the 2 fuel hoses.

Temporarily install the No. 1, No. 2 and No. 3 injection pipes with the union nuts.

Install the No. 2 and No. 3 injection pipe clamps with the bolt and 2 nuts, as shown in the illustration.

Torque:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

HINT:

If the painted mark on the No. 1 injection pipe has disappeared, use the illustration as a reference to install the clamps.

Using union nut wrench, tighten the injection pipe union nuts on the common rail side.

Torque:

32 N*m{326 kgf*cm, 24 ft.*lbf} for use with union nut wrench

35 N*m{357 kgf*cm, 26 ft.*lbf} for use without union nut wrench

HINT:

Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

Using union nut wrench, tighten the injection pipe union nuts on the injector side.

Torque:

32 N*m{326 kgf*cm, 24 ft.*lbf} for use with union nut wrench

35 N*m{357 kgf*cm, 26 ft.*lbf} for use without union nut wrench

HINT:

Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

Temporarily install the No. 4 injection pipe with the union nuts.

Install 2 new injection pipe clamps with the 2 bolts.

Torque:

13 N*m{133 kgf*cm, 10 ft.*lbf}

NOTICE:

1. Make sure that the inner-rubbers of the injection pipe fit inside the clamps.
   
2. When installing the pipe, check that the inner-rubbers and the clamps are in their proper positions.
   

Using union nut wrench, tighten the injection pipe union nut on the common rail side.

Torque:

32 N*m{326 kgf*cm, 24 ft.*lbf} for use with union nut wrench

35 N*m{357 kgf*cm, 26 ft.*lbf} for use without union nut wrench

HINT:

Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

Using union nut wrench, tighten the injection pipe union nut on the injector side.

Torque:

32 N*m{326 kgf*cm, 24 ft.*lbf} for use with union nut wrench

35 N*m{357 kgf*cm, 26 ft.*lbf} for use without union nut wrench

HINT:

Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

Install a new O-ring to the guide.

Apply a small amount of clean engine oil to the O-ring.

Install the guide with the bolt.

Torque:

8.0 N*m{82 kgf*cm, 71 in.*lbf}

Install the injection pipe clamp with the bolt.

Torque:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

Install the stay with the 2 bolts.

Torque:

19 N*m{194 kgf*cm, 14 ft.*lbf}

HINT:

The stay's indented area (labeled A) must face the manifold.

Install a new gasket and the EGR valve.

Install 2 new gaskets and the pipe with the 2 nuts and 2 bolts.

Torque:

13 N*m{133 kgf*cm, 10 ft.*lbf}

HINT:

The gasket's claws should be on the pipe side.

Install a new gasket and the air connector with the 2 nuts and bolt.

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

Install the bracket with the 3 bolts.

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

Install a new gasket and the throttle body with the 2 bolts and 2 nuts.

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

Connect the throttle control motor connector.

Connect the throttle position sensor connector.

Install the bracket with the 2 bolts.

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

Connect the vacuum hoses to the 3 locations.

Connect the 2 connectors.

Install the charge air cooler with intake air connector (Toyota Fortuner RM0000015B6002X.html).

Check that there are no leaks from any part of the fuel system when the engine is stopped. If there is fuel leakage, repair or replace parts as necessary.

Start the engine and check that there are no leaks from any part of the fuel system. If there is fuel leakage, repair or replace parts as necessary.

Disconnect the return hose from the common rail.

Start the engine and check for fuel leaks from the return pipe.
If there is fuel leakage, replace the common rail.

Connect the intelligent tester to the DLC3.

Start the engine and push the intelligent tester main switch on.

Select the Fuel Leak test from the Active Test mode on the intelligent tester.

If the intelligent tester is not available, fully depress the accelerator pedal quickly. Increase the engine speed to the maximum and maintain that speed for 2 seconds. Repeat this operation several times.

Check that there are no leaks from any part of the fuel system.

NOTICE:

A return pipe leakage of less than 10 cc (0.6 cu in.) per minute is acceptable.

Reconnect the return hose to the common rail.

Install the cover with the 3 bolts and 2 nuts.

Torque:

7.0 N*m{71 kgf*cm, 62 in.*lbf}