In this chapter the Toyota tacoma Intake Manifold replacing procedure details are mentioned.
The Intake manifold replacing for 3RZ-FE Engine,5vz-FE Engine,2TR-FE Engine,2RZ-FE Engine,and 1gr-FE Engine is provided.
All details and required diagrams are provided to make this task easier.
Intake Manifold
REMOVAL & INSTALLATION Details are as follows:---
Properly relieve the fuel system pressure.
Properly disarm the SRS system
Disconnect the negative battery cable.
Drain the engine coolant. Remove the air cleaner assembly.
Disconnect the fuel injector wiring connectors.
Remove the necessary components in order to gain access to the intake manifold retaining bolts.
Remove the intake manifold retaining bolts. Remove the intake manifold from the engine.
1gr-FE Engine
To install:
- Clean all surfaces.
- Install a new gasket on each cylinder head.
NOTEAlign the ports of the gasket and the cylinder head. Be careful of the installation direction. Position the intake manifold to the engine. - Install the retaining bolts and tighten to specification, in an alternating sequence.
- Continue the installation in the reverse order of the removal procedure.
- Be sure to fill the cooling system with the proper grade and type engine coolant.
- Start the engine and check for leaks. Correct as required.
- Relieve the fuel system pressure.
- Disconnect the negative battery cable.
- Drain the engine coolant.
- Remove or disconnect the following:
Air cleaner cap
Mass Air Flow (MAF) meter and the resonator
Accelerator cable from the throttle body, if equipped with a manual transaxle
Accelerator and throttle cables from the throttle body, if equipped with an automatic transaxle
Intake air connector
Air conditioning idle-up valve, if equipped with air conditioning
No. 1 and No. 2 Positive Crankcase Ventilation (PCV) hoses
Spark plug wires from the spark plugs
Throttle body
Air conditioning compressor connector, if equipped with air conditioning
Oil pressure sensor connector
Engine Coolant Temperature (ECT) sensor connector
Exhaust Gas Recirculation (EGR) gas temperature sensor connector
EGR Vacuum Switching Valve (VSV) connector
- Disconnect the engine wiring harness, as follows:
2 bolts and the harness from the intake chamber
5 engine harness clamps and harness
- Remove or disconnect the following:
Knock (KS) sensor connector
Crankshaft Position (CKP) sensor connector
Fuel pressure control VSV connector
Data Link Connector 1 (DLC1) from the bracket
2 engine wiring harness clamps
Engine wiring harness
Fuel injectors
EGR valve and vacuum modulator
Intake chamber stay, by removing the 2 bolts
Fuel return pipe, by removing the hoses and 2 bolts
- Remove the intake chamber, as follows:
Vacuum hose, from the gas filter
Brake booster vacuum hose, from the intake chamber
3 bolts, 2 nuts, air intake chamber and gasket
- Remove the fuel inlet tube, by removing the union bolts
- Remove the delivery pipe and injectors, as follows:
Vacuum hose, from the fuel pressure regulator
Bolts and delivery pipe together with the 4 injectors
4 insulators, from the 4 spacers
Injectors from the delivery pipe
O-ring and grommet, from each injector
- Remove or disconnect the following:
Intake manifold, by removing the 3 bolts and 2 nuts
Gasket
To install:
- Clean the intake manifold surfaces.
- Install or connect the following:
New gasket
Intake manifold. Tighten the bolts and nuts to 22 ft. lbs. (30 Nm).
- Install the injectors to the delivery pipe, as follows:
NOTECheck that the injectors rotate smoothly.
New grommet to the injector
New O-ring onto the injector, by lubricating it with gasoline
Injectors to the delivery pipe
Injector with the connector facing upward
Injectors and delivery pipe. Tighten the bolts to 15 ft. lbs. (21 Nm).
Fuel tube, with new gaskets. Tighten the union bolts to 22 ft. lbs. (30 Nm).
- Install the air intake chamber, as follows:
New gasket
Air intake chamber. Tighten the bolts and nuts to 15 ft. lbs. (21 Nm).
Vacuum hose, to the gas filter
Brake booster vacuum hose, to the intake chamber
- Install or connect the following:
Fuel return pipe
Intake chamber stay. Tighten the bolts to 14 ft. lbs. (20 Nm).
EGR valve and vacuum modulator
Injector connectors
- Connect the engine wiring harness to the engine, as follows:
Engine wiring harness to the intake manifold
Engine wiring harness clamps
DLC1 to the bracket
Fuel pressure control VSV connector
KS sensor connector
CKP sensor connector
5 engine wiring harness clamps
Engine wiring harness, to the intake chamber
- Install or connect the following:
EGR VSV connector
EGR gas temperature sensor connector
ECT sensor connector
Oil pressure sensor connector
Compressor connector, if equipped with air conditioning
Throttle body
Spark plug wires, to the spark plugs
No. 1 and No. 2 PCV hoses
Air conditioning idle up valve, if equipped with air conditioning
Air intake connector
Accelerator cable, to the throttle body, if equipped with a manual transaxle
Throttle and accelerator cables to the throttle body, if equipped with automatic transaxle
MAF meter, resonator and the air cleaner cap
Negative battery cable
- Refill the cooling system.
- Start the engine and check for leaks.
- Check the ignition timing. Road test the vehicle for proper operation.
- Recheck all fluid levels.
Fig. Intake manifold and related components-2.4L and 2.7L (3RZ-FE/M) engines
Fig. Intake manifold and related components-2.7L (2TR-FE) engine
- Before servicing the vehicle, refer to the Precautions Section.
- Properly relieve the fuel system pressure.
- Properly disarm the SRS system
- Disconnect the negative battery cable.
- On 4WD and PreRunner, remove the engine undercover subassembly.
- Drain the engine coolant. Remove the air intake connector.
- Remove the throttle body and motor assembly. Disconnect the fuel hoses.
- Disconnect the fuel vapor feed hose from the VSR. Disconnect the vacuum hose. Remove the bolt, and then remove the clamp bracket.
- Disconnect the number two water bypass hose. Disconnect the number three ventilation hose. Disconnect the VSV connector.
- Disengage the engine wire harness clamp. Disconnect the air conditioning compressor magnetic clutch connector.
- Disengage the wire harness clamp. Remove the bolt and harness clamp bracket. Disconnect the three connectors.
- Remove the retaining nut inside the relay block. Disconnect the engine wire harness from the relay block.
- Remove the five bolts and two nuts retaining the intake manifold in place. Remove the intake manifold from the engine.
To install:
- Clean all surfaces.
- Install a new gasket onto the intake manifold. Position the intake manifold to the engine.
- Install the retaining bolts and tighten to specification, in an alternating sequence.
- Continue the installation in the reverse order of the removal procedure.
- Be sure to fill the cooling system with the proper grade and type engine coolant.
- Start the engine and check for leaks. Correct as required.
- Before servicing the vehicle, refer to the Precautions Section.
- Relieve the fuel system pressure.
- Disconnect the negative battery cable.
- Drain the engine coolant.
- Remove or disconnect the following:
Air cleaner cap
Mass Air Flow (MAF) meter and resonator
Accelerator cable, from the throttle body, if equipped with a manual transaxle
Accelerator and throttle cables, from the throttle body, if equipped with an automatic transaxle
Intake air connector
Air conditioning idle-up valve, if equipped with air conditioning
No. 1 and No. 2 PCV hoses
Spark plug wires, from the spark plugs
Throttle body
- Detach the following connectors:
Air conditioning compressor connector, if equipped with air conditioning
Oil pressure sensor connector
Engine Coolant Temperature (ECT) sensor connector
Exhaust Gas Recirculation (EGR) gas temperature sensor connector
EGR Vacuum Switching Valve (VSV) connector
- Disconnect the engine wiring harness, as follows:
Engine wiring harness, from the intake chamber
5 engine wiring harness clamps and engine wiring harness
Knock (KS) sensor connector
Crankshaft Position (CKP) sensor connector
Fuel pressure control VSV connector
Data Link Connector 1 (DLC1), from the bracket
2 engine wiring harness clamps.
Engine wiring harness from the engine
- Remove or disconnect the following:
Fuel injectors
EGR valve and vacuum modulator
Intake chamber stay
Fuel return pipe
- Remove the intake chamber, as follows:
Vacuum hose, from the gas filter
Brake booster vacuum hose, from the intake chamber
Intake chamber and gasket
Fuel inlet tube, by removing the union bolts
- Remove the delivery pipe and injectors, as follows:
Vacuum hose, from the fuel pressure regulator
Delivery pipe, with the 4 injectors
4 insulators, from the 4 spacers
4 injectors, from the delivery pipe
O-ring and grommet, from each injector
- Remove or disconnect the following:
Intake manifold
Gasket
To install:
- Clean the intake manifold surfaces.
- Install or connect the following:
New gasket
Intake manifold. Tighten the bolts and nuts to 22 ft. lbs. (30 Nm).
- Install the injectors to the delivery pipe, as follows:
New grommet onto the injector
New O-ring onto the injector, lubricated with gasoline
Injectors onto the delivery pipe, with the electrical connector upward
- Install or connect the following:
NOTECheck that the injectors rotate smoothly.
Delivery pipe. Tighten the bolts to 15 ft. lbs. (21 Nm).
Fuel tube, with new gaskets. Tighten the union bolts to 22 ft. lbs. (30 Nm).
- Install the air intake chamber, as follows:
Air intake chamber with a new gasket. Tighten the bolts and nuts to 15 ft. lbs. (21 Nm).
Vacuum hose, to the gas filter
Brake booster vacuum hose, to the intake chamber
- Install or connect the following:
Fuel return pipe
Intake chamber stay. Tighten the bolts to 14 ft. lbs. (20 Nm).
- Install the EGR valve and vacuum modulator, as follows:
New gasket, EGR valve and vacuum modulator. Tighten the bolt to 74 inch lbs. (9 Nm) and the nuts to 14 ft. lbs. (19 Nm).
Vacuum hoses, to the EGR VSV
Water bypass hose
EGR pipe, using new gaskets. Tighten the bolts to 14 ft. lbs. (18 Nm), intake manifold nuts to 14 ft. lbs. (19 Nm) and the cylinder head nuts to 15 ft. lbs. (20 Nm).
Injector connectors
- Connect the engine wiring harness to the engine, as follows:
Engine wiring harness, to the intake manifold
2 engine wiring harness clamps
DLC1, to the bracket
Fuel pressure control VSV connector
KS sensor connector
CKP sensor connector
5 engine wiring harness clamps.
Engine wiring harness, to the intake chamber
- Attach the following connectors to the engine:
EGR VSV connector
EGR gas temperature sensor connector
ECT sensor connector
Oil pressure sensor connector
Compressor connector, if equipped with air conditioning
- Install or connect the following:
Throttle body
Spark plug wires, to the spark plugs
No. 1 and No. 2 PCV hoses
Air conditioning idle up valve, if equipped with air conditioning
Air intake connector, by installing the 2 bolts, hose clamp and 2 air hoses
Accelerator cable, if equipped with a manual transaxle
Throttle and accelerator cables, if equipped with an automatic transaxle
MAF meter, resonator and the air cleaner cap
Negative battery cable
- Refill the cooling system.
- Start the engine and check for leaks.
- Check the ignition timing. Road test the vehicle for proper operation.
- Recheck all fluid levels.
- Before servicing the vehicle, refer to the Precautions Section.
- Disconnect the negative battery cable.
- Relieve the fuel system pressure.
- Drain the engine coolant.
- Remove or disconnect the following:
Spark plug wires from the spark plugs
Air cleaner cap
Mass Air Flow (MAF) meter and resonator
Actuator cable with the bracket, if equipped with cruise control
Accelerator cable
Throttle cable, if equipped with an automatic transmission
Exhaust Gas Recirculation (EGR) pipe and gaskets, if equipped with an EGR valve
Oil filler tube and No. 1 throttle cable clamp, by removing the bolt and 2 nuts
Intake chamber stay, by removing the 2 bolts
Vacuum Switching Valve (VSV) connector, for the fuel pressure control
Throttle Position (TP) sensor connector
Idle Air Control (IAC) valve connector
EGR gas temperature connector, if equipped with an EGR valve
VSV connector for the EGR valve, if equipped with an EGR valve
Disconnect the Positive Crankcase Ventilation (PCV) hoses
Water bypass hoses
Air assist hose from the intake air connector
2 vacuum sensing hoses from the VSV
Evaporative Emission (EVAP) hose
Air hose from the power steering
Air hose from the air conditioning idle up valve, if equipped with air conditioning
Air intake chamber assembly
Engine wiring harness from the intake air connector
2 fuel return hoses
Brake booster vacuum hose, from the intake air connector
Ground strap, from the intake air connector
Data Link Connector 1 (DLC1) from the intake air connector bracket
Idle up valve connector, if equipped with air conditioning
Intake air connector
Upper radiator hose, from the engine
Oil pressure sensor connector
Crankshaft Position (CKP) sensor connector
6 injector connectors
Engine Coolant Temperature (ECT) sender gauge connector
ECT sensor connector
Knock (KS) sensor connector
Camshaft Position (CMP) sensor connector
3 engine wiring harness clamps
Engine wiring harness, from the cylinder head
Fuel pressure regulator
Heater hose
Camshaft Position sensor.
Fuel inlet hose
Intake manifold stay
Intake manifold assembly
To install:
- Clean all surfaces.
- Install or connect the following:
New gaskets
Intake manifold assembly. Tighten the bolts and nuts to 13 ft. lbs. (18 Nm).
Intake manifold stay. Tighten the bolts to 13 ft. lbs. (18 Nm).
Fuel inlet hose
CMP sensor. Tighten it to 71 inch lbs. (8 Nm).
Engine wiring harness to the cylinder head
3 engine wiring harness clamps
Oil pressure sensor connector
CKP sensor connector
6 injector connectors
ECT sender gauge connector
ECT sensor connector
KS sensor connector
CMP sensor connector
Heater hose
Intake manifold. Tighten the bolts and nuts to 14 ft. lbs. (18.5 Nm).
DLC1 to the bracket on the intake manifold
Ground strap to the intake manifold
Brake booster vacuum hose, to the intake air connector
2 fuel return hoses
Engine wiring harness to the intake manifold
Idle up valve connector, if equipped with air conditioning
Air intake chamber assembly to the engine. Tighten the bolts and nuts to 14 ft. lbs. (18.5 Nm).
PCV hoses
Water bypass hoses
Air assist hose to the intake manifold
2 vacuum sensing hoses to the VSV
EVAP hose
Air hose to the power steering
Air hose to the air conditioning idle up valve, if equipped with air conditioning
VSV connector for the fuel pressure control
TP sensor connector
IAC valve connector
EGR gas temperature connector, if equipped with an EGR valve
VSV connector for the EGR valve, if equipped with an EGR valve
Intake chamber stay. Tighten the bolts to 30 ft. lbs. (40 Nm).
New O-ring to the oil filler tube
Oil filler tube end into the tube hole in the oil pan
Oil filler tube and No. 1 throttle cable clamp
New gaskets and the EGR pipe. Tighten the clamp nuts to 71 inch lbs. (8 Nm) and the EGR pipe nuts to 14 ft. lbs. (18 Nm).
Fuel pressure regulator
3 clamps for the spark plug wires, to the No. 2 timing belt cover
CMP connector to the No. 2 timing belt cover
Upper radiator hose
- Fill with engine coolant.
- Install or connect the following:
Spark plug wires to the spark plugs
Actuator cable with the bracket, if equipped with cruise control
Accelerator cable
Throttle cable, if equipped with an automatic transmission
Air cleaner hose
Negative battery cable
- Fill the radiator with engine coolant.
- Start the engine and check for leaks.
These details will help.
Thanks.
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