Question 1

How to remove the intake manifold on Toyota Highlander?

Accepted Answer

Before starting the removal of the 2GR-FE intake manifold users must first drain the fuel system pressure. Initially remove the assembly of the engine under cover then take off the No. 1 engine under cover. The first step includes draining the engine coolant followed by removing the V-bank cover sub-assembly. The work requires removal of front wiper assemblies and blades from both sides before moving on to extract cowl top ventilator louver and windshield wiper system and link along with the outer cowl top panel assembly. To commence work begin by taking off the air cleaner cap sub-assembly along with disconnecting the engine room main wire through the removal of its 5 harness clamps. First remove the No. 1 surge tank stay by following the specified order for bolt removal, and secondly, uninstall the throttle body bracket once its two bolts are removed in sequence. You should disconnect the intake air surge tank assembly by removing four hoses which include vapor feed hose and vacuum hose and disconnect the throttle body connector and clamp. Also remove the 2 water by-pass hoses from the throttle body. A 5 mm socket hexagon wrench should be used to remove the 4 bolts and 2 nuts in accordance with the specified order before extracting the gasket from the intake air surge tank. Proceed by removing the No. 2 engine mounting stay RH through the use of 5 bolts together with 2 nuts. The procedure calls for fuel main tube disconnection by removing the No. 2 fuel pipe clamp followed by pinching the tube connector then pulling out the fuel pipe to avoid dirt entry into the quick connector. Use 6 fuel injector connector disconnectors to remove the 5 bolts that secure the fuel delivery pipe sub-assembly with 6 fuel injectors being careful about accidental drops of the injectors. To remove the intake manifold first untighten six bolts followed by four nuts per the specific order before extracting the gaskets between No. 1 intake manifold and the heads.

Question 2

How to remove and install the intake manifold on Toyota Tundra?

Accepted Answer

The first step to remove the intake manifold involves releasing fuel system pressure along with disconnecting the negative battery cable terminal while keeping in mind that system initialization might be required upon reinstalled cable connections. Begin by removing the Number 1 engine under cover followed by draining the engine coolant supply then taking away the front wiper motor with its link assembly. The front cowl top outer panel subassembly can be untapped after washer hose removal and 7 bolts are unscrewed. The removal process starts with 2 bolted nuts on the V-bank cover followed by the disconnecting operations of the No. 2 air cleaner hose and air cleaner assembly with element. The procedure demands disconnection of No. 2 ventilation hose before detaching the hose clamp then unplugging the vacuum hose and MAF meter connector. While using a clip remover detach wire harness clamps allow for loosening the hose clamp to expose the final 2 bolts until removal. Remove the intake air surge tank by disconnecting all hoses and connectors then unfastening wire harness clamps while also removing bolts and stays until you can detach the tank with an 8 mm hexagon wrench along with its gasket. The first step involves removing the fuel delivery pipe sub-assembly together with the intake manifold sub-assembly once you detach the 10 bolts, intake manifold, and exchange the 2 gaskets. Place new gaskets on each cylinder head port holes before setting the intake manifold across the cylinder heads. Tighten the 10 bolts evenly to 26 N.m (265 kgf.cm, 19 ft.lb) torque while starting with the inner bolts. You must first secure the fuel delivery pipe sub-assembly and then add the intake air surge tank using a new gasket before bolting it with four fasteners and two nuts at 28 N.m (286 kgf. cm, 21 ft.lbf) torque settings and installing surge tank stays with each bolt tightened to 21 N.m (214 kgf. cm, 15 ft.lbf). Connect several hoses while positioning the clamps correctly before attaching the oil baffle plate with a bolt at 9.0 N.m (92 kgf. cm, 80 in.lbf). The air cleaner assembly with element needs installation using 2 bolts that should be tightened to 8.0 N.m (82 kgf. cm, 71 in.lbf). After that install the hose clamp to the required protrusion height and connect the MAF meter connector and additional hoses. The practice involves installing the air cleaner hose No. 2 before reconnecting the negative terminal battery cable. Then, add coolant and check for any fluid leaks. Install the V-bank cover with 2 nuts at 7.5 N.m (76 kgf.cm, 66 in.lbf) and install the front cowl top outer panel with 7 bolts at the same torque. Finally, reconnect the 2 washer hoses, install the front wiper motor with its link assembly then end with the No. 1 engine under cover.

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