Toyota 17120-50020 Manifold, Intake

The upper intake manifold, otherwise known as the Intake Air Surge Tank as used by Toyota, needs the nut on the negative terminals of the battery to be loosened before a cover of the engine, the air intake duct and the air filter housing can be removed. This is followed by coolant hoses from the throttle body where one needs to be, clamped off and disconnected from the nipple, which should be repeated on the other side of the car as well; the EVAP system fuel vapor feed hose should be disconnected along with the ventilation hose and throttle body wiring. Conventional connectors on the Vacuum Switching Valve have to be disconnected, and the bolts of the throttle body bracket needs to be unscrewed so that the bracket is removed. The baffle plate located ahead of the engine coupled with the two intake manifold support brackets referred to as surge tank stays have to be removed together with the bolts and nuts under the intake manifold to unbolster the upper intake manifold. The condition of the upper intake manifold gasket must be ascertained and if it is to be okay it can be put back for use. That is, installation occurs in the reverse sequence so that the mounting bolts, as well as nuts, are tightened to the desired torque. As for the lower intake manifold which Toyota refers to as Intake manifold, the removal of the upper intake manifold is a Sure necessity. When changing the lower intake manifold, the fuel rail is to be removed; whereas, if replacing gaskets only, unbolting the fuel supply/reject connections is enough. The lower intake manifold bolts are then removed to take out the manifold and old gaskets should be thrown away and the two mating surfaces ought to be cleaned well. New gaskets must be used during installation, and the lower INTAKE MANIFOLD BOLTS should be tightened to the specified torque.

To remove the lower intake manifold, first relieve the fuel system pressure. Disconnect the cable from the negative battery terminal and remove the throttle body. Clearly label and detach all remaining wires, hoses, and brackets attached to the upper intake manifold. Remove the mounting bolt for the EVAP vacuum switching valve and separate it from the upper intake manifold. Evenly loosen the intake manifold fasteners, making several passes to avoid warping, then remove the mounting nuts and bolts to detach the upper intake manifold from the lower intake manifold, taking care not to pry between the gasket mating surfaces if it is stuck. When removing the upper intake manifold, note that it can remain attached to the lower manifold if access to other components is needed, while the throttle body can also stay attached if the coolant hoses are clamped off and disconnected. Next, remove the fuel rail and injectors, then label and detach all remaining wires, hoses, and brackets attached to the lower intake manifold, coolant outlets, and rear coolant bypass casting. Remove the mounting nuts and bolts to detach the intake manifold from the cylinder heads, starting with the outer bolts and working inward, ensuring even separation to avoid damage. For installation, remove all traces of old gasket material and sealant from the upper and lower intake manifolds and cylinder heads, cleaning the mating surfaces with brake system cleaner while plugging the cylinder head ports with rags. Install new gaskets, position the lower intake manifold on the engine, and install the fasteners, tightening them in three or four equal steps from the center outwards to avoid warping. Install a new gasket and the upper intake manifold onto the lower intake manifold, then install and tighten the nuts and bolts in the same manner. Finally, install the remaining parts in reverse order of removal, check the coolant level, and run the engine to check for fuel, vacuum, and coolant leaks around the throttle body hoses.

The upper intake manifold, referred to by Toyota as the intake air surge tank, requires the disconnection of the negative battery terminal, removal of the engine cover, and the air intake duct along with the air filter housing. Next, coolant hoses from the throttle body should be clamped off and disconnected, followed by the disconnection of the EVAP system fuel vapor feed hose, ventilation hose, and throttle body wiring. Two Vacuum Switching Valve electrical connectors need to be disconnected, and the throttle body bracket bolts should be removed to take off the bracket. The baffle plate must be removed, along with both bolts from each intake manifold support bracket, which Toyota calls surge tank stays, before removing the two intake manifold mounting nuts and four mounting bolts to detach the upper intake manifold. The condition of the upper intake manifold gasket should be checked, replacing it if necessary, and installation follows the reverse order of removal, ensuring that the mounting bolts and nuts are tightened to the specified torque. For the lower intake manifold, known as the intake manifold by Toyota, the upper intake manifold must first be removed. If replacing the lower intake manifold, the fuel rail should be removed; however, if only replacing gaskets, disconnecting the fuel supply and return line connections is sufficient. The lower intake manifold bolts should be removed to detach the manifold, and old gaskets must be discarded while cleaning the mating surfaces thoroughly. Installation is again the reverse of removal, using new gaskets and ensuring the bolts are tightened to the specified torque.

Regarding the 2UZ-FE engines, it is recommended to start with the following operations, turning on the ignition and relieving the fuel system pressure and disconnecting the cable of the negative terminal of the battery. Depending on your vehicle, the upper intake manifold comes off after the throttle body is detached, and after this, label and disconnect any wires, hoses and brackets that are connected to the throttle body. Set the mounting bolt for the EVAP vacuum switching valve aside, then loosen the intake manifold fasteners by turning them on and off around evenly and at last, disconnect the upper intake manifold with the lower intake manifold, but if doing so, do not apply any force between gasket surfaces. If getting to the other parts, the upper intake manifold does not have to be removed from the lower one, and the throttle body does not have to be disconnected as well if the coolant hoses are clamped off. Subsequently, disconnect all the wires, hoses and brackets from the lower intake manifold, the fuel rail and injectors have to be removed and identified, and the lower intake manifold has to be unbolted from the cylinder heads, starting from outermost bolts to avoid damages. For 1UR-FE, 3UR-FE, and 3UR-FBE engines the following components have to be detached, the engine cover, the windshield wiper motor and the linkage, cowl panel bolts, and the cooling system should be drained; besides, the air intake duct and the throttle body should be removed. Bolt, label, and remove all the wires, hoses, and brackets from the intake manifold, all water bypass hoses, and fuel rail insulators also need to be removed. Remove the intake manifold from the cylinder heads in the same manner as the bolts; outer nuts first before the inner ones. For the installation on 2UZ-FE engines, first, remove all the old gasket materials from the intake manifolds and cylinder heads, and then new gaskets must be put in their place, put the lower intake manifold into its place correctly and finally, tighten the fasteners in m stages to the desired torque of 11 N-m. Place a new gasket and the upper intake manifold with torque in same way, then put the rest of the parts back in the reverse way. Moreover, look for the coolant level, start the engine and look for any sign of leakage. Regarding 1UR-FE, 3UR-FE, and 3UR-FBE engines, remove old gasket pieces, put the new gaskets in their place, set the intake manifold, fasten its bolts with lsd tightening indications, and reinstall all the remaining parts and the liquid to fill in the cooling system and check for leakage.