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Intake Manifold: Removal

WARNING: This page is about a different variant/trim than selected.
  1. DISCHARGE FUEL SYSTEM PRESSURE 

    HINT:

    (See FUEL SYSTEM ).

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    CAUTION: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
  3. REMOVE THROTTLE BODY ASSEMBLY 
    1. Remove the throttle body assembly (See ON-VEHICLE INSPECTION ).
  4. DISCONNECT INLET HEATER WATER HOSE  (See REMOVAL )
  5. DISCONNECT OUTLET HEATER WATER HOSE  (See REMOVAL )
  6. REMOVE VACUUM SWITCHING VALVE ASSEMBLY (for ACIS) 
    1. Disconnect the 2 vacuum hoses, 2 union to connector tube hoses, clamp and connector.
    2. Remove the bolt and vacuum switching valve assembly (for ACIS).
    Fig 1: Locating Vacuum Hoses, Connector Tube Hoses, Clamp And Connector
    G06115162Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. DISCONNECT NO. 2 VENTILATION HOSE 
    1. Disconnect the No. 2 ventilation hose from the intake manifold.
    Fig 2: Locating No. 2 Ventilation Hose
    G05998755Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. DISCONNECT UNION TO CONNECTOR TUBE HOSE 
    1. Disconnect the union to connector tube hose from the intake manifold.
  9. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY  (See REMOVAL )
  10. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY  (See INSPECTION )
    Fig 3: Locating Connector Tube Hose
    G05998757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE INTAKE MANIFOLD 
    1. Disconnect the 4 clamps and wire harness.
      Fig 4: Identifying Clamps And Wire Harness
      G06115165Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and 2 wire harness brackets.
      Fig 5: Locating Bolts And Wire Harness Brackets
      G06031313Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the fuel vapor feed hose, vacuum hose, clamp and connector.
    4. Remove the bolt and wire harness bracket.
      Fig 6: Locating Fuel Vapor Feed Hose, Vacuum Hose, Clamp And Connector
      G06115167Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Apply battery voltage to the terminals of the connector to close the tumble control valves.

      Standard 

      TESTER CONNECTION SPECIFIED CONDITION CHART

      Tester Connection Specified Condition
      Positive battery voltage applied to terminal 8 (M-), and negative battery voltage applied to terminal 4 (M+) Open → Closed
      Fig 7: Identifying Tumble Control Valve Connectors
      G05998751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If this procedure is not performed, the valves may be damaged when the intake manifold is removed.
      • Apply battery voltage for 1 to 3 seconds.
      • If battery voltage is applied for more than 3 seconds, the actuator may be damaged.
      • Do not allow the lead wires to contact the other terminals.
    6. Remove the bolt.
    7. Detach the 2 clamps from the intake manifold and bracket.
    8. Disconnect the intake air control valve actuator connector.
      Fig 8: Identifying Clamps, Intake Manifold And Bracket
      G05998752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Remove the 6 bolts and intake manifold.
      NOTE: The valves may be damaged if they are not closed before removing the intake manifold.
      Fig 9: Locating Bolts And Intake Manifold
      G06031317Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Remove the intake manifold gasket from the intake manifold.
    Fig 10: Locating Intake Manifold Gasket And Intake Manifold
    G06115171Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE CHECK VALVE 
    1. Disconnect the 2 vacuum hoses from the intake manifold and remove the check valve.
    Fig 11: Locating Vacuum Hoses, Intake Manifold And Check Valve
    G06031319Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE WIRING HARNESS CLAMP BRACKET 
    1. Remove the bolt and bracket.
    Fig 12: Identifying Bolt And Bracket
    G05998759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE ENGINE MOUNTING DAMPER 
    1. Remove the 3 bolts and engine mounting damper.
  15. REMOVE INTAKE AIR CONTROL VALVE ACTUATOR (for TCV)  (See INTAKE AIR CONTROL VALVE ACTUATOR (FOR TCV) )
Fig 13: Locating Bolts And Engine Mounting Damper
G06031321Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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