Toyota 17120-0D040
Intake Manifold

The first step for intake manifold removal consists of disconnecting the engine unit and generator together with ignition coils and spark plugs and injectors. Start by disconnecting the 2 heated oxygen sensor connectors before removing the 2 heated oxygen sensors. Then uninstall the 4 bolts with upper heat insulator, 4 bolts with 2 exhaust manifold stays and finally remove the 5 nuts for the exhaust manifold and gasket. Following the detachment of connectors containing the heated oxygen sensor (bank 1 sensor 1), camshaft timing oil control valve, crankshaft position sensor, knock sensor, oil pressure switch, camshaft position sensor, ECT sensor, throttle position sensor, throttle control motor, accelerator position sensor, IAC valve, and noise filter the 2 bolts are removed and followed by disconnecting the 2 ground straps and engine wire. Mandatory first step involves caps and hoses from the PCV system then continues with removal of the assembly unit that includes throttle body and intake manifold by unmounting 2 water lines and 2 vacuum lines followed by elimination of 4 bolts and 2 nuts and 2 wire brackets. You must start by evenly loosening and removing the 19 bearing cap bolts and 9 bearing caps to access the gasket, camshaft timing chain, timing sprocket, VVT sprocket, camshaft timing oil control valve together with camshafts. The cylinder head assembly requires removal of the water bypass pipe bolt followed by gradual removal of the ten cylinder head bolts while respecting their specific sequence then taking off the ten plate washers before gently removing the cylinder head. The repair procedure requires removal of the camshaft timing oil control valve filter together with the camshaft position sensor and ECT sensor. Before installation clean all parts of the engine and apply fresh engine oil on slip and rotational components while replacing each gasket and oil seal. The mechanic should first position the new cylinder head gasket onto the cylinder block followed by gentle placement of the cylinder head. The bolt installation ends in a light engine oil application before a uniform tightening process then consists of paint marking the cylinder head bolt front for future retightening. Attach the water bypass pipe bolt before linking the upper radiator hose with the heater hose and setting in place the two camshafts joined to the cylinder head and fixing the bearing caps while tightening their bolts. Reposition the timing sprocket, VVT timing sprocket and timing chain before placing the camshaft position sensor and oil filler cap together with the camshaft timing oil control valve, filter. The intake manifold and throttle body assembly receive a new gasket before installation of vacuum and water hoses together with PCV valve and hoses and the engine wire with its required connectors. Place the exhaust manifold that contains a new gasket and follow with the installation of injectors along with spark plugs and ignition coils and generator and engine unit.