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Home >> Toyota >> 2015 >> Highlander LE Plus, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 108 (Intake / Exhaust System (2GR-FXE) (Service Information) (Hybrid)) >> Intake Manifold >> Removal [02/2014 - 11/2016] >> Procedure

Removal [02/2014 - 11/2016]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. PRECAUTION 
    NOTE:

    After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notice before proceeding with work.

    Refer to PRECAUTION [02/2014 - 11/2016]

  2. DISCHARGE FUEL SYSTEM PRESSURE 

    Refer to PRECAUTION [02/2014 - 11/2016]

  3. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to REMOVAL [02/2014 - 11/2016]

  4. REMOVE INTAKE AIR SURGE TANK ASSEMBLY 
    1. Disconnect the No. 1 fuel vapor feed hose from the intake air surge tank assembly.
      GTY298865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 5 clamps and separate the engine wire from the vehicle body.
      GTY298860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Slide the clip and disconnect the ventilation hose from the intake air surge tank assembly.
      GTY298861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the manifold absolute pressure sensor connector.
      GTY298862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disengage the wire harness clamp from the No. 1 surge tank stay.
      GTY423394Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 2 bolts in the order shown in the illustration.
    7. Remove the No. 1 surge tank stay from the intake air surge tank assembly and cylinder head cover sub-assembly.
    8. Remove the 2 bolts in the order shown in the illustration.
      Fig 1: No. 1 Surge Tank Stay Loosening Sequence
      GTY428586Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Remove the throttle body bracket from the intake air surge tank assembly and cylinder head cover sub-assembly.
    10. Using a 5 mm hexagon socket wrench, remove the 4 bolts and 2 nuts from the intake air surge tank assembly in the order shown in the illustration.
      Fig 2: Intake Air Surge Tank Assembly Loosening Sequence
      GTY431234Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    11. Remove the 3 air surge tank to intake manifold gaskets from the intake air surge tank assembly.
      GTY306245Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. SEPARATE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 

    Refer to PROCEDURE - Step 32 , or refer to PROCEDURE - Step 32

  6. REMOVE RESERVOIR BRACKET 

    Refer to PROCEDURE - Step 33 , or refer to PROCEDURE - Step 33

  7. REMOVE NO. 2 EGR PIPE 

    Refer to PROCEDURE - Step 4

  8. REMOVE EGR DELIVERY CHAMBER 
    1. Slide the 2 clips and disconnect the No. 7 water by-pass hose and No. 8 water by-pass hose from the EGR valve assembly.
      GTY442701Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 7 Water By-pass Hose
      *2 No. 8 Water By-pass Hose
    2. Disconnect the EGR valve assembly connector.
    3. Remove the EGR delivery chamber from the intake manifold.
      GTY304357Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the No. 2 intake manifold gasket from the intake manifold.
      GTY304367Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE NO. 2 ENGINE MOUNTING STAY RH (for Engine Mounting Stay Side) 

    Refer to PROCEDURE - Step 34 , or refer to PROCEDURE - Step 34

  10. REMOVE NO. 2 ENGINE MOUNTING STAY RH (for Intake Manifold Side) 
    1. GTY298828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the bolt and No. 2 engine mounting stay RH from the intake manifold.

  11. DISCONNECT FUEL TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 7

  12. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 8

  13. REMOVE INTAKE MANIFOLD 
    1. Remove the 6 bolts, 4 nuts and intake manifold from the cylinder head sub-assembly LH and RH.
      GTY308314Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 intake manifold to head gaskets from the cylinder head sub-assembly LH and RH.
      GTY304368Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE STUD BOLT 

    HINT: 

    If a stud bolt is deformed or the threads are damaged, replace it.

    1. Using an E6 "TORX" socket wrench, remove the 2 stud bolts from the intake manifold.
      GTY444976Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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