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Home >> Toyota >> 2018 >> Prius Two Eco >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Exhaust/ Intake System - Service Information >> Intake Manifold >> Removal [11/2015 -] >> Procedure

Removal [11/2015 -]: Procedure

  1. REMOVE THROTTLE BODY ASSEMBLY 

    Refer to REMOVAL [11/2015 -]

  2. REMOVE RADIATOR SUPPORT OPENING COVER 

    Refer to PROCEDURE - Step 2 [11/2015 - 12/2018] , or refer to PROCEDURE - Step 2 [12/2018 -]

  3. REMOVE INLET NO. 2 AIR CLEANER 
    1. Loosen the hose clamp.
      GTY543988Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and inlet No. 2 air cleaner from the inlet No. 1 air cleaner and upper radiator support sub-assembly.
  4. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 
    1. Remove the air cleaner filter element sub-assembly from the air cleaner case sub-assembly.
      GTY543979Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE AIR CLEANER CASE SUB-ASSEMBLY 
    1. Remove the 2 bolts and air cleaner case sub-assembly from the air cleaner bracket.
      GTY543990Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE AIR CLEANER BRACKET 
    1. Remove the 3 bolts and disengage the wire harness clamp to remove the air cleaner bracket from the cylinder block sub-assembly and air conditioning wire.
      GTY543991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE INLET NO. 1 AIR CLEANER 
    1. Remove the 2 bolts and inlet No. 1 air cleaner from the intake manifold.
      GTY598710Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE EGR PIPE ASSEMBLY 
    1. Remove the 4 bolts and EGR pipe assembly from the intake manifold and EGR valve assembly.
      GTY543985Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the inlet EGR gasket from the intake manifold.
      GTY543986Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the EGR pipe gasket from the EGR valve assembly.
      GTY543987Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE E.F.I. VACUUM SENSOR ASSEMBLY (MANIFOLD ABSOLUTE PRESSURE SENSOR) 
    1. Disconnect the E.F.I. vacuum sensor assembly (manifold absolute pressure sensor) connector.
      GTY555681Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the vacuum hose from the intake manifold.
    3. Remove the bolt and E.F.I. vacuum sensor assembly (manifold absolute pressure sensor) from the intake manifold.
  10. DISCONNECT VENTILATION HOSE 
    1. Slide the clip and disconnect the ventilation hose from the intake manifold.
      GTY544040Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. DISCONNECT ENGINE WIRE 
    1. Disengage the 2 clamps.
      GTY598722Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the engine water pump assembly connector.
    3. Remove the bolt and disconnect the wire harness bracket.
      GTY544042Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the 4 fuel injector assembly connectors and purge valve (purge VSV) connectors.
      GTY544034Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the bolt and disengage the clamp to disconnect the engine wire.
  12. DISCONNECT ENGINE COVER BRACKET 
    1. Remove the bolt and disconnect the engine cover bracket from the intake manifold.
      GTY544036Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. DISCONNECT NO. 8 WATER BY-PASS HOSE 
    1. Disengage the 2 hose clamps.
      GTY544037Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Slide the clip and disconnect the No. 8 water by-pass hose from the No. 3 water by-pass pipe.
  14. DISCONNECT NO. 2 FUEL VAPOR FEED HOSE 
    1. Disengage the 2 hose clamps and disconnect the No. 2 fuel vapor feed hose from the intake manifold.
      GTY598721Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the No. 2 fuel vapor feed hose from the intake manifold.
      GTY544039Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. DISCONNECT WATER BY-PASS HOSE 
    1. Disengage the 2 hose clamps and disconnect the water by-pass hose from the intake manifold.
      GTY563334Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Water By-Pass Hose
      *2 No. 2 Water By-pass Hose
    2. Disengage the 2 hose clamps and disconnect the No. 2 water by-pass hose from the intake manifold.
  16. REMOVE INTAKE MANIFOLD 
    1. Remove the 3 bolts and 2 nuts and intake manifold from the cylinder head sub-assembly.
      GTY571744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
  17. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET 
    1. Remove the No. 1 intake manifold to head gasket from the intake manifold.
      GTY544028Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE STUD BOLT (w/ 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.
      GTY598724Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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