Question 1

How to install the intake manifold sub-assembly on Toyota Tundra?

Accepted Answer

During the installation process of the 1GR-FE engine intake manifold sub-assembly begin by applying new gaskets to each cylinder head while ensuring port holes match up properly and the installation orientation is accurate. Position the intake manifold onto the cylinder heads and gradually tighten its 10 bolts to 26 Nm (265 kgf-cm, 19 ft-lbf) while completing several torque passes starting from the internal bolts towards the exterior bolts. The second step in this procedure demands the installation of the fuel delivery pipe sub-assembly. Add a new gasket to the intake air surge tank before tightening it using a 8-mm hexagon wrench to apply 4 bolts and 2 nuts to a torque of 28 Nm (286 kgf-cm, 21 ft-lbf). Secure the No. 2 surge tank stay together with No. 1 surge tank stay through 2 bolts each at 21 Nm (214 kgf-cm, 15 ft-lbf). The procedure requires attaching the single baffle plate bolt to 9.0 Nm torque while you also connect the wire harness clamp before adding throttle body bracket bolts at 21 Nm torque. You must attach the vacuum switching valve (for ACIS) connector with two wire harness clamps while correctly fitting the No. 1 ventilation hose and its union to check valve hose and purge VSV connector and purge line hose. The No. 4 and No. 5 water by-pass hoses should be connected with the throttle position sensor and throttle control motor connector. You need to install the air cleaner assembly with its element by tightening 2 bolts at 8.0 Nm (82 kgf-cm, 71 in-lbf) while also setting the hose clamp to maintain a protrusion of less than 0.5 mm (0.0197 in.) before connecting the MAF meter connector along with 2 wire harness clamps and the vacuum hose with tightened clamp. Safely insert the grommet pin for the No. 2 air cleaner hose and mount it with 2 bolts at 7.5 Nm (76 kgf-cm, 66 in-lbf). Tighten the hose clamp to 4.0 Nm (41 kgf-cm, 35 in-lbf). Reconnect the negative terminal cable of the battery while remembering any system which demands system initialization afterward. Engine coolant should be added while searching for both coolant and fuel leakage. After installing 2 V-bank cover nuts at 7.5 Nm (76 kgf-cm, 66 in-lbf), continue to put on 7 front cowl top outer panel bolts also at 7.5 Nm (76 kgf-cm, 66 in-lbf) before connecting both washer hoses. The final step entails putting on the front wiper motor along with its link assembly and the Number 1 engine under cover.

Question 2

How to remove the intake manifold on Toyota Tundra?

Accepted Answer

The first step to remove an intake manifold on a 1GR-FE engine demands a fuel system pressure discharge. After disconnecting the negative battery cable you should note that some systems need a reset once you reconnect it. The first task is to remove the No. 1 under engine cover and drain all engine coolant from the system. Start by removing the front wiper motor and links and then disconnect the front cowl top outer panel sub-assembly through the process of unclipping two washer hoses and removing seven bolts. Start by uninstalling the V-bank cover through the process of removing its 2 nuts. To begin the process remove the No. 2 air cleaner hose by first releasing the clamp fastener and following with the removal of 2 bolts. Start by disconnecting the No. 2 ventilation hose and detaching its hose clamp and vacuum hose as well as separating the MAF meter connector and detaching 2 wire harness clamps using a clip remover before loosening the hose clamp to remove the 2 bolts of the air cleaner assembly with element. To work on the intake air surge tank, you must disconnect eight elements: throttle position sensor and throttle control motor connector with the No. 4 and No. 5 water by-pass hoses, purge line hose, purge VSV connector and union to check valve hose, and finally the No. 1 ventilation hose along with the vacuum switching valve connector. Start by using a clip remover to detach wire harness clamps then remove 2 bolts holding the throttle body bracket, the clamp and bolt from the wire harness and finally uninstall the No. 1 and No. 2 surge tank stays by removing 2 bolts. Finish the process by unscrewing the 2 nuts then use an 8 mm hexagon wrench to detach 4 bolts from around the intake air surge tank and gasket. Remove the fuel delivery pipe sub-assembly followed by the intake manifold sub-assembly by taking out the 10 bolts and two gaskets and the intake manifold.

OEM Toyota Tundra Intake Manifold

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Toyota Tundra Intake Manifold

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