Intake Manifold: Removal: Removal

DISCHARGE FUEL SYSTEM PRESSURE
Refer to PRECAUTION
DRAIN ENGINE COOLANT . Refer to REPLACEMENT - Step 1

REMOVE V-BANK COVER

Raise the front of the V-bank cover to disengage the 2 pins.

Fig 1: Removing V-Bank Cover

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	Pin
*2	Hook
*3	No. 1 V-bank Cover Bracket

Disengage the 2 hooks and remove the V-bank cover from the No. 1 V-bank cover bracket.

REMOVE AIR CLEANER HOSE ASSEMBLY
1. Loosen the hose clip and disconnect the ventilation hose from the air cleaner hose assembly.
  
  Fig 2: Identifying Bolt, Clamps & Air Cleaner Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the vacuum hose from the air cleaner hose assembly.
3. Disengage the clamp and disconnect the wire harness from the air cleaner hose assembly.
4. Remove the bolt and disconnect the air cleaner hose assembly from the resonator bracket.
5. Loosen the 2 hose clamps and remove the air cleaner hose assembly from air cleaner cap sub-assembly and intake air surge tank.
DISCONNECT NO. 1 AIR INJECTION SYSTEM HOSE (w/ Secondary Air Injection System)
1. Loosen the hose clip and disconnect the No. 1 air injection system hose from the air hose assembly.
  
  Fig 3: Identifying No. 1 Air Injection System Hose (W/ Secondary Air Injection System)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AIR HOSE ASSEMBLY (w/ Secondary Air Injection System)
1. Remove the bolt and disconnect the air hose assembly from the timing chain cover sub-assembly.
  
  Fig 4: Identifying Air Tube Assembly Clamp And Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Loosen the hose clip and disconnect the air hose assembly from the No. 1 emission control valve set.
3. Remove the 2 bolts and disconnect the air hose assembly from the timing chain cover sub-assembly and No. 1 surge tank stay.
  
  Fig 5: Identifying Air Tube Assembly Clamp And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Loosen the hose clip and remove the air hose assembly from the No. 2 emission control valve set.
REMOVE INTAKE AIR SURGE TANK
1. Disconnect the throttle with motor body assembly connector.
  
  Fig 6: Identifying Water By-Pass Hoses & Throttle Body Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Loosen the 2 hose clips and disconnect the No. 4 water by-pass hose and No. 5 water by-pass hose from the water inlet housing.
3. Disconnect the 2 clamps of the heater water hose from the intake air surge tank.
  
  Fig 7: Identifying Heater Hose Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Loosen the hose clip and disconnect the No. 1 fuel vapor feed hose from the vacuum switching valve.
  
  Fig 8: Identifying No. 1 Vacuum Switching Valve & No. 1 Fuel Vapor Feed Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Disconnect the No. 1 vacuum switching valve connector.
6. Loosen the hose clip and disconnect the No. 1 ventilation hose from the intake air surge tank.
  
  Fig 9: Identifying Heater Water Hose Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Remove the bolt and disconnect the wire harness clamp bracket from the No. 2 surge tank stay.
  
  Fig 10: Identifying Wire Harness Clamp Bracket And No. 2 Surge Tank Stay
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Remove the 2 bolts and No. 2 surge tank stay from the intake air surge tank.
9. Disengage the clamp and disconnect the wire harness from the No. 1 surge tank stay.
  
  Fig 11: Disconnecting The Wire Harness
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Remove the 2 bolts and No. 1 surge tank stay from the intake air surge tank.
  
  Fig 12: Identifying Bolts & No. 1 Surge Tank Stay
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. Remove the 2 bolts and throttle body bracket from the intake air surge tank.
  
  Fig 13: Identifying Bolts & Throttle Body Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. Using an 8 mm socket hexagon wrench, remove the 4 bolts, 2 nuts and intake air surge tank from the intake manifold.
  
  Fig 14: Identifying Intake Air Surge Tank And Fasteners
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *1 Nut
13. Remove the air surge tank to intake manifold gasket from the intake air surge tank.
REMOVE REAR CYLINDER HEAD COVER . Refer to REMOVAL - Step 3
DISCONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY . Refer to REMOVAL - Step 4
DISCONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY . Refer to REMOVAL - Step 5
REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY . Refer to REMOVAL - Step 6
REMOVE INTAKE MANIFOLD
1. Remove the bolt and the wire harness clamp bracket from the intake manifold.
  
  Fig 15: Identifying Wire Harness Clamp Bracket And Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 4 nuts, 6 bolts and intake manifold from the cylinder head sub-assembly.
  
  Fig 16: Identifying Intake Manifold And Fasteners
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *1 Nut
3. Remove the No. 1 intake manifold to head gasket and No. 2 intake manifold to head gasket from the cylinder head sub-assembly.
REMOVE STUD BOLT
1. Using "Torx" socket wrench E8, remove the 2 stud bolts from the intake manifold.
  
  Fig 17: Identifying Intake Manifold Studs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002