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Home >> Toyota >> 2009 >> Highlander Limited, FWD >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Intake (2GR-FE) >> Intake Manifold >> Removal

Intake Manifold: Removal

  1. DISCHARGE FUEL SYSTEM PRESSURE 

    (See REMOVAL )

  2. REMOVE ENGINE UNDER COVER ASSEMBLY  (See REMOVAL )
  3. REMOVE NO. 1 ENGINE UNDER COVER  (See REMOVAL )
  4. DRAIN ENGINE COOLANT  (See COOLANT )
  5. REMOVE V-BANK COVER SUB-ASSEMBLY  (See REMOVAL )
  6. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See REMOVAL )
  7. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See REMOVAL )
  8. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  (See REMOVAL )
  9. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY  (See REMOVAL )
  10. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY  (See REMOVAL )
  11. REMOVE AIR CLEANER CAP SUB-ASSEMBLY  (See INSTALLATION )
  12. DISCONNECT ENGINE ROOM MAIN WIRE 
    1. Disconnect the 5 harness clamps.
    Fig 1: Identifying Harness Clamps
    G05414983Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE THROTTLE BODY BRACKET 
    1. Remove the 2 bolts in the order shown in the illustration and remove the throttle body bracket.
    Fig 2: Locating Bolts And Throttle Body Bracket
    G05414984Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE NO. 1 SURGE TANK STAY 
    1. Remove the 2 bolts in the order shown in the illustration and remove the No. 1 surge tank stay.
    Fig 3: Locating Bolts And No. 1 Surge Tank Stay
    G05414985Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE INTAKE AIR SURGE TANK ASSEMBLY 
    1. Disconnect the 4 hoses.

      HINT:

      • A: vapor feed hose
      • B: union to check valve hose
      • C: No. 1 ventilation hose
      • D: vacuum hose
      Fig 4: Locating Hoses
      G05414986Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the throttle body connector and clamp.
    3. Disconnect the connector.
      Fig 5: Identifying Throttle Body Connector And Clamp
      G05414987Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the 2 water by-pass hoses from the throttle body.
      Fig 6: Identifying Water By-Pass Hoses
      G05414988Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 4 bolts and 2 nuts in the order shown in the illustration.

      HINT:

      Use a 5 mm socket hexagon wrench to remove the 4 bolts.

    6. Remove the gasket from the intake air surge tank.
    Fig 7: Identifying Intake Air Surge Tank Bolts In Sequence
    G05414989Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE NO. 2 ENGINE MOUNTING STAY RH 
    1. Remove the 5 bolts [E].
    2. Remove the 2 nuts [F].
    3. Remove the No. 2 engine mounting stay RH.
    Fig 8: Locating No. 2 Engine Mounting Stay RH Nuts And Bolts
    G05414990Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. DISCONNECT FUEL MAIN TUBE 
    1. Remove the No. 2 fuel pipe clamp.
    2. Pinch the tube connector and pull out the fuel pipe.
    NOTE:
    • Check that there is no dirt or other foreign objects around the connector before disconnecting it. Clean the connector as necessary.
    • It is necessary to prevent dirt or foreign objects from entering the quick connector. If dirt or foreign objects enter the connector, the O-rings may not seal properly.
    • Only disconnect the quick connector by hand.
    • Do not bend, kink or twist the nylon tubes. Protect the connector by covering it with a plastic bag.
    • If the pipe and the connector are stuck, carefully try wiggling or pushing and pulling on the connector to release it. Pull the connector off the pipe carefully.
    Fig 9: Pinching Tube Connector
    G04975007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY 
    1. Disconnect the 6 fuel injector connectors.
      Fig 10: Locating Fuel Injector Connectors
      G04975008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 5 bolts and fuel delivery pipe sub-assembly together with the 6 fuel injectors.
      NOTE: Be careful not to drop the fuel injectors when removing the fuel delivery pipe sub-assembly.
      Fig 11: Locating Bolts And Fuel Delivery Pipe Sub-Assembly
      G04975009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 6 injector vibration insulators from the intake manifold.
    Fig 12: Locating Injector Vibration Insulators And Intake Manifold
    G05138184Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE INTAKE MANIFOLD 
    1. Remove the 6 bolts and 4 nuts in the order shown in the illustration and remove the intake manifold.
    2. Remove the 2 No. 1 intake manifold to head gaskets.
    Fig 13: Locating No. 1 Intake Manifold Bolts And Nuts
    G05414995Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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