A: A 2ZR-FE engine requires pressure discharge from the fuel system as a first step for intake manifold removal. Beginning with disconnecting the cable from the negative terminal you should remove engine under covers on opposite sides of the vehicle. The first steps include draining engine coolant before removing the No. 2 cylinder head cover. You must first disassemble the air cleaner cap sub-assembly unit with hose before you separate the engine wire harness and remove the harness bracket. The technician disconnects both the No. 1 fuel vapor feed hose and vacuum hose before removing the fuel pipe clamp to separate the fuel tube sub-assembly. The maintenance procedure starts with removal of the fuel delivery pipe sub-assembly as well as both the No. 1 delivery pipe spacer and the injector vibration insulator. Separate both the starter assembly and the flywheel housing side cover before beginning. To access the oil cooler tube requires a union nut wrench for successful separation of both inlet No. 1 and outlet No. 1 oil cooler tubes at each union while another wrench holds the unions first before removing the bolt and clamping it. Remove the transmission oil level gauge sub-assembly through a process of dipstick removal along with breather hose disconnect and bolt removal. Take off both the engine oil level dipstick while also removing the throttle body assembly. The process ends with clamps off the 4 wire harness followed by ventilation hose disconnection and dissasembly of the intake manifold and its stay requiring 4 bolts and 2 nuts.
Q: How to install the intake manifold on Scion xB?
A: Installation of the 2AZ-FE intake manifold begins with securing the throttle hose then adding the union to connector tube hose and tightening the vacuum hose clamp bolt to 8.5 Nm (87 kgf-cm, 75 in-lbf). Following the installation of the No. 2 ventilation hose you must place a new gasket onto the intake manifold before tightening the 5 bolts and 2 nuts to 30 Nm (306 kgf-cm, 22 ft-lbf). Reattach the union to connector tube hose together with the No. 2 ventilation hose. Following the installation of the cylinder head injector vibration insulation pieces (4) position the first delivery pipe spacer while securing both fuel delivery pipe sub-assemblies with 2 bolts tightened to 20 Nm (204 kgf-cm, 15 ft-lbf). The fuel tube sub-assembly needs to be installed with wire harness which should be followed by connecting both the injector assembly connector and camshaft oil control valve assembly connector and heated oxygen sensor connector. The installer must install the EFI pipe clamp before attaching the fuel tube sub-assembly. To complete the installation you should place the throttle body assembly followed by the air cleaner cap sub-assembly with No.1 air cleaner hose then the No.1 engine cover sub-assembly. The installation order includes cowl top outer panels together with front wiper motor links and ventilator louver assemblies for left and right sides and hood to cowl top seals and front wiper arms and blades for left and right sides and windshield wiper arm covers. As a final step add engine coolant while ensuring the coolant system does not have any leaks.