Toyota 17120-0T011
Intake Manifold

Before handling the intake manifold of 2ZR-FE engines it is essential to discharge fuel system pressure. First disconnect the cable from the negative battery terminal before removing the engine under covers from both left and right sides. The first step includes draining engine coolant followed by taking off the No. 2 cylinder head cover. Starting with step two requires removal of the air cleaner cap sub-assembly with attached hose followed by disconnecting the engine wire harness. Then remove the harness bracket. First disconnect the No. 1 fuel vapor feed hose and vacuum hose before unclipping and disconnecting the fuel tube sub-assembly components. The first step involves removing the fuel delivery pipe sub-assembly before taking out both the No. 1 delivery pipe spacer along with the injector vibration insulator. Use a union nut wrench to detach both inlet and outlet No. 1 oil cooler tubes from their union while gripping the tube union with a wrench before removing its bolt and tube clamp. First disconnect the breather hose from the transmission oil level gauge sub-assembly and remove the bolt along with taking out the dipstick. First disconnect the engine oil level dipstick and the throttle body assembly. The last step requires the removal of intake manifold and intake manifold stay through separating 4 bolts and 2 nuts with ventilation hose disconnection and 4 wire harness clamp separation.

First step for removing an intake manifold from a 2ZR-FE engine is to drain all engine coolant. Begin by taking out the No. 2 cylinder head cover then execute the removal of air cleaner cap sub-assembly along with the throttle body assembly. You should begin the intake manifold removal by detaching the wire harness bracket followed by bolt removal then disconnecting three hoses before taking out four bolts and two nuts and removing the intake manifold stay and finally extracting the intake manifold. You need to remove both the intake manifold gasket followed by the bolt accompanied by the bracket. remove the two stud bolts from the intake manifold by using a "TORX" socket E6.

Installing the 2ZR-FE intake manifold begins with torquing the "TORX" socket E6 through 2 stud bolts until they reach 5.0 Nm (51 kgf-cm, 44 in-lbf). Install the bracket first using a bolt which should be tightened to 10 Nm (102 kgf-cm, 8 ft-lbf) while placing a new gasket inside the intake manifold. After placing the intake manifold alongside the intake manifold stay apply 4 bolts together with 2 nuts until the torque reaches 28 Nm (286 kgf-cm, 21 ft-lbf). The 3 hoses should be connected after users torque the wire harness bracket to 10 Nm (102 kgf-cm, 8 ft-lbf) using a bolt. The throttle body assembly requires installation before moving to the air cleaner cap sub-assembly and then the No. 2 cylinder head cover. The fluid capacity should be checked before adding engine coolant while conducting a systematic leak inspection.

Discharging fuel system pressure while separating the negative cable connection from the battery terminal represents the first step to remove the 2AZ-FE engine intake manifold. System initialization is possible after reconnecting if needed. The first step involves removing the front wiper arm head cap then proceeding to uninstall both left and right front wiper arm assemblies with their blades. Unfasten the sequence starting with the hood to cowl top seal as well as the right/left cowl top ventilator louvers and the windshield wiper motor and link assembly. The necessary components for cleaning include the outer cowl top panel as well as the suspension tower damper assembly (when using a front strut bar) and the No. 1 engine cover sub-assembly. Remove all fluid from the engine coolant storage and then proceed to take off both the throttle body assembly and air cleaner cap sub-assembly with its attached hose. Start the fuel main tube and No. 2 ventilation hose removal before disconnecting the fuel delivery pipe sub-assembly. Intake manifold removal begins by disconnecting tubing from the union to the hose at the No. 2 hose to hose tube and continuing with disconnecting the camshaft timing oil control valve connector and wire harness clamp and finally removing the vacuum hose clamp tubing from the union. The first step involves removing the five bolts, two nuts and the intake manifold before taking the gasket off the intake manifold.

Connect the ventilation hose and the 4 wire harness clamps.

Secure the intake manifold and intake manifold stay using 4 bolts and 2 nuts, tightening to 28 Nm (286 kgf-cm, 21 ft-lbf).

Install the throttle body assembly and the air cleaner cap sub-assembly with hose.