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Intake Manifold: Removal

NOTE: While the battery is connected, even if the power switch is OFF, the brake control system activates when the brake pedal is depressed or the door courtesy switch turns on. Therefore during servicing of the brake system components, do not operate the brake pedal or open/ close the doors while the battery is connected.
  1. REMOVE LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY  (See REMOVAL )
  2. REMOVE BATTERY SERVICE HOLE COVER LH  (See REMOVAL )
  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
    NOTE:
    • When disconnecting the cable, some systems need to be initialized after the cable is reconnected (see INITIALIZATION ).
    • After the power switch is turned OFF, the HDD navigation system requires approximately 6 minutes to record various types of memory and settings. As a result, after turning the power switch OFF, wait 6 minutes or more before disconnecting the cable from the negative (-) battery terminal.
  4. REMOVE SERVICE PLUG GRIP  (See REMOVAL )
  5. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH  (See REMOVAL )
  6. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH  (See REMOVAL )
  7. REMOVE NO. 1 ENGINE UNDER COVER  (See REMOVAL )
  8. DRAIN ENGINE COOLANT  (See REPLACEMENT )
  9. REMOVE V-BANK COVER SUB-ASSEMBLY  (See REMOVAL )
  10. REMOVE AIR CLEANER INLET COVER SUB-ASSEMBLY  (See REMOVAL )
  11. REMOVE ENGINE ROOM SIDE COVER RH  (See REMOVAL )
  12. REMOVE ENGINE ROOM SIDE COVER LH  (See REMOVAL )
  13. REMOVE NO. 1 AIR CLEANER INLET  (See REMOVAL )
  14. REMOVE INTAKE AIR CONNECTOR PIPE  (See REMOVAL )
  15. REMOVE AIR CLEANER ASSEMBLY LH  (See REMOVAL  )
  16. REMOVE AIR CLEANER ASSEMBLY RH  (See REMOVAL  )
  17. DISCONNECT NO. 1 MOTOR COOLING PIPE  (See REMOVAL )
  18. REMOVE SKID CONTROL ECU  (See REMOVAL )
  19. DISCONNECT NO. 3 RELAY BLOCK  (See REMOVAL )
  20. DISCONNECT BRAKE FLUID RESERVOIR  (See REMOVAL )
  21. REMOVE SKID CONTROL ECU BRACKET  (See REMOVAL )
  22. REMOVE ENGINE COVER SUB-ASSEMBLY LH  (See REMOVAL )
  23. REMOVE NO. 6 COVER SUB-ASSEMBLY  (See REMOVAL )
  24. REMOVE ENGINE ROOM ECU COVER  (See REMOVAL )
  25. REMOVE OUTLET ENGINE ROOM ECM DUCT  (See REMOVAL )
  26. DISCONNECT HYBRID VEHICLE CONTROL ECU CONNECTOR 
    1. Disconnect the connector from the hybrid vehicle control ECU.
      Fig 1: Locating Hybrid Vehicle Control ECU Connector
      G05773214Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE NO. 2 CONNECTOR HOLDER 
    1. Disconnect the 3 connectors.
    2. Detach the wire harness's clamp A from the ECM box
    3. Detach the 2 claws and remove the No 2 connector holder.
      Fig 2: Identifying No. 2 Connector Holders
      G05773215Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. DISCONNECT ECM CONNECTOR 
    1. Disconnect the 4 ECM connectors and remove the engine wire harness from the ECM box.
      2. Fig 3: Locating ECM Connectors
      G05773216Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. DISCONNECT ENGINE WIRE HARNESS 
    1. Disconnect the engine wire harness connectors.

      HINT.

      To disconnect the 4 injector driver connectors, (1) push the claw downward and (2) move the lock lever to release the lock.

    2. Using a clip remover, detach the 4 engine wire harness clamps labeled A
    3. Disconnect the 3 engine wire harness clamps labeled B
    4. Remove the 4 bolts and disconnect the 4 ground cables.
    5. Remove the 3 bolts and disconnect the 3 wire harness brackets.
    6. Remove the 4 nuts and disconnect the engine wire harness protector from the intake manifold.
      Fig 4: Locating Ground Cable And Wire Harness Bracket
      G05773217Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE INJECTOR DRIVER 
    1. Disconnect the 4 injector driver connectors as follows" (1) push the claw downward, and (2) move the lock lever to release the lock.
      2. Fig 5: Disconnecting Injector Driver Connectors
      G05773218Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a clip remover, detach the 3 wire harness clamps.
    3. Remove the 2 bolts, 2 nuts and injector driver
      4. Fig 6: Locating Injector Driver Bolts And Nuts
      G05773219Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the No. 1 engine cover.
  31. REMOVE FLEXIBLE HOSE BRACKET SUB-ASSEMBLY 
    1. Disconnect the flexible hose.
    2. Remove the bolt and flexible hose bracket
      Fig 7: Locating Bolt And Flexible Hose Bracket
      G05773220Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE ENGINE MOTOR CABLE CLAMP BRACKET 
    1. Using a clip remover, detach the wire harness clamp
    2. Remove the bolt and engine motor cable clamp bracket.
      3. Fig 8: Locating Engine Motor Cable Clamp Bracket Bolt
      G05773221Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE NO. 3 ENGINE COVER SUB-ASSEMBLY  (See REMOVAL )
  34. REMOVE THROTTLE BODY ASSEMBLY  (See REMOVAL )
  35. REMOVE WATER BY-PASS PIPE HOSE 
    1. Disconnect the 4 water hoses and remove the 2 bolts and water by-pass pipe hose.
      Fig 9: Locating Water Hoses And Bolts
      G04948139Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE PURGE VSV 
    1. Disconnect the VSV connector
    2. Disconnect the 2 purge line hoses
      3. Fig 10: Locating Purge Line Hoses
      G04948140Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt and VSV.
  37. DISCONNECT PCV HOSE 
    1. Disconnect the PCV hose from the intake manifold
      Fig 11: Locating PCV Hose
      G04948141Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE INTAKE MANIFOLD 
    1. Remove the 8 bolts, 2 nuts and intake manifold
      2. Fig 12: Locating Intake Manifold Bolts And Nuts
      G04948142Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 gaskets
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