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Home >> Toyota >> 2017 >> Highlander XLE, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 209 (Intake / Exhaust System (2GR-FXS) - Service Information - (Hybrid)) >> Intake Manifold >> Removal [11/2016 - ] >> Procedure

Removal [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 notices before proceeding with work.

    Refer to PRECAUTION [11/2016 - ]

  2. DISCHARGE FUEL SYSTEM PRESSURE 

    Refer to PRECAUTION [11/2016 - ]

  3. REMOVE V-BANK COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 22

  4. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to REMOVAL [11/2016 - ]

  5. DISCONNECT VENTILATION HOSE 
    1. Slide the clip and disconnect the ventilation hose from the intake air surge tank assembly.
      GTY731927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. DISCONNECT PURGE VALVE (PURGE VSV) 
    1. Disconnect the No. 1 fuel vapor feed hose from the intake air surge tank assembly.
      GTY691170Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and disconnect the purge valve (purge VSV) from the intake air surge tank assembly.
  7. REMOVE NO. 2 SURGE TANK STAY 
    1. Remove the 2 bolts and No. 2 surge tank stay from the intake air surge tank assembly and camshaft housing sub-assembly.
      GTY731925Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE INTAKE AIR SURGE TANK ASSEMBLY 
    1. Disengage the 2 wire harness clamps and disconnect the E.F.I. vacuum sensor assembly (manifold absolute pressure sensor) connector.
      GTY691171Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and disconnect the water hose clamp from the intake air surge tank assembly.
      GTY691172Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 5 bolts, 2 nuts and intake air surge tank assembly from the intake manifold.
      GTY689213Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
  9. REMOVE AIR SURGE TANK TO INTAKE MANIFOLD GASKET 
    1. Remove the air surge tank to intake manifold gasket from the intake air surge tank assembly.
      GTY650180Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE NO. 1 V-BANK COVER BRACKET 

    HINT: 

    Perform this procedure only when replacement of a No. 1 V-bank cover bracket is necessary.

    1. Remove the 2 No. 1 V-bank cover brackets from the intake air surge tank assembly.
      GTY650181Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE E.F.I. VACUUM SENSOR ASSEMBLY (MANIFOLD ABSOLUTE PRESSURE SENSOR) 
    1. Remove the bolt and E.F.I. vacuum sensor assembly (manifold absolute pressure sensor) from intake air surge tank assembly.
      GTY680811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. SEPARATE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 

    Refer to PROCEDURE - Step 32

  13. REMOVE RESERVOIR BRACKET 

    Refer to PROCEDURE - Step 33

  14. REMOVE NO. 2 ENGINE MOUNTING STAY RH 
    1. Disengage the wire harness clamp from the wire harness clamp bracket.
      GTY696256Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Fuel Tube Sub-assembly Connector
      *b EGR Valve Assembly Connector
    2. Disconnect the fuel tube sub-assembly connector.
    3. Disconnect the EGR valve assembly connector.
    4. Remove the bolt and disconnect the wire harness clamp bracket from the No. 2 engine mounting stay RH.
      GTY691210Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the bolt, 2 nuts and No. 2 engine mounting stay RH from the engine moving control rod.
      GTY708005Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    6. GTY691212Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  15. REMOVE NO. 2 EGR PIPE 
    1. Remove the 2 bolts and 2 nuts and disconnect the No. 2 EGR pipe from the intake manifold and EGR valve assembly.
      GTY720166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    2. Using an E6 "TORX" socket wrench, remove the stud bolt from the intake manifold.
      GTY691205Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the No. 2 EGR pipe.
  16. REMOVE NO. 2 EGR PIPE GASKET 
    1. Remove the No. 2 EGR pipe gasket from the No. 2 EGR pipe.
      GTY650202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the No. 2 EGR pipe gasket from the EGR valve assembly.
      GTY731933Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. DISCONNECT FUEL TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 7

  18. REMOVE FUEL DELIVERY PIPE WITH SENSOR ASSEMBLY 

    Refer to PROCEDURE - Step 8

  19. REMOVE NO. 1 DELIVERY PIPE SPACER 

    Refer to PROCEDURE - Step 9

  20. REMOVE INJECTOR VIBRATION INSULATOR 

    Refer to PROCEDURE - Step 10

  21. REMOVE INTAKE MANIFOLD 
    1. Remove the 4 bolts, 4 nuts and intake manifold from the cylinder head sub-assembly LH and cylinder head sub-assembly RH.
      GTY646786Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
  22. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET 
    1. Remove the 2 No. 1 intake manifold to head gaskets from the cylinder head sub-assembly LH and cylinder head sub-assembly RH.
      GTY650203Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. 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 3 stud bolts from the intake manifold.
      GTY691206Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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