Toyota Tacoma 2002-06

Intake Manifold

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Removal & Installation



1gr-FE Engine


Click image to see an enlarged view

Fig. Intake manifold and related components-4.0L engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Properly disarm the SRS system
  6.  
  7. Disconnect the negative battery cable.
  8.  
  9. Drain the engine coolant. Remove the air cleaner assembly.
  10.  
  11. Disconnect the fuel injector wiring connectors.
  12.  
  13. Remove the necessary components in order to gain access to the intake manifold retaining bolts.
  14.  
  15. Remove the intake manifold retaining bolts. Remove the intake manifold from the engine.
  16.  

To install:

  1. Clean all surfaces.
  2.  
  3. Install a new gasket on each cylinder head.
    NOTE
    Align the ports of the gasket and the cylinder head. Be careful of the installation direction. Position the intake manifold to the engine.

  4.  
  5. Install the retaining bolts and tighten to specification, in an alternating sequence.
  6.  
  7. Continue the installation in the reverse order of the removal procedure.
  8.  
  9. Be sure to fill the cooling system with the proper grade and type engine coolant.
  10.  
  11. Start the engine and check for leaks. Correct as required.
  12.  

2RZ-FE Engine
  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the engine coolant.
  6.  
  7. 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
     

  8.  
  9. Disconnect the engine wiring harness, as follows:

    2 bolts and the harness from the intake chamber
     
    5 engine harness clamps and harness
     

  10.  
  11. 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
     

  12.  
  13. 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
     

  14.  
  15. Remove the fuel inlet tube, by removing the union bolts
  16.  
  17. 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
     

  18.  
  19. Remove or disconnect the following:

    Intake manifold, by removing the 3 bolts and 2 nuts
     
    Gasket
     

  20.  

To install:

  1. Clean the intake manifold surfaces.
  2.  
  3. Install or connect the following:

    New gasket
     
    Intake manifold. Tighten the bolts and nuts to 22 ft. lbs. (30 Nm).
     

  4.  
  5. Install the injectors to the delivery pipe, as follows:
    NOTE
    Check 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).
     

  6.  
  7. 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
     

  8.  
  9. 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
     

  10.  
  11. 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
     

  12.  
  13. 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
     

  14.  
  15. Refill the cooling system.
  16.  
  17. Start the engine and check for leaks.
  18.  
  19. Check the ignition timing. Road test the vehicle for proper operation.
  20.  
  21. Recheck all fluid levels.

    Click image to see an enlarged view

    Fig. Intake manifold and related components-2.4L and 2.7L (3RZ-FE/M) engines

  22.  

2TR-FE Engine


Click image to see an enlarged view

Fig. Intake manifold and related components-2.7L (2TR-FE) engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Properly disarm the SRS system
  6.  
  7. Disconnect the negative battery cable.
  8.  
  9. On 4WD and PreRunner, remove the engine undercover subassembly.
  10.  
  11. Drain the engine coolant. Remove the air intake connector.
  12.  
  13. Remove the throttle body and motor assembly. Disconnect the fuel hoses.
  14.  
  15. Disconnect the fuel vapor feed hose from the VSR. Disconnect the vacuum hose. Remove the bolt, and then remove the clamp bracket.
  16.  
  17. Disconnect the number two water bypass hose. Disconnect the number three ventilation hose. Disconnect the VSV connector.
  18.  
  19. Disengage the engine wire harness clamp. Disconnect the air conditioning compressor magnetic clutch connector.
  20.  
  21. Disengage the wire harness clamp. Remove the bolt and harness clamp bracket. Disconnect the three connectors.
  22.  
  23. Remove the retaining nut inside the relay block. Disconnect the engine wire harness from the relay block.
  24.  
  25. Remove the five bolts and two nuts retaining the intake manifold in place. Remove the intake manifold from the engine.
  26.  

To install:

  1. Clean all surfaces.
  2.  
  3. Install a new gasket onto the intake manifold. Position the intake manifold to the engine.
  4.  
  5. Install the retaining bolts and tighten to specification, in an alternating sequence.
  6.  
  7. Continue the installation in the reverse order of the removal procedure.
  8.  
  9. Be sure to fill the cooling system with the proper grade and type engine coolant.
  10.  
  11. Start the engine and check for leaks. Correct as required.
  12.  

3RZ-FE Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Drain the engine coolant.
  8.  
  9. 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
     

  10.  
  11. 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
     

  12.  
  13. 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
     

  14.  
  15. Remove or disconnect the following:

    Fuel injectors
     
    EGR valve and vacuum modulator
     
    Intake chamber stay
     
    Fuel return pipe
     

  16.  
  17. 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
     

  18.  
  19. 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
     

  20.  
  21. Remove or disconnect the following:

    Intake manifold
     
    Gasket
     

  22.  

To install:

  1. Clean the intake manifold surfaces.
  2.  
  3. Install or connect the following:

    New gasket
     
    Intake manifold. Tighten the bolts and nuts to 22 ft. lbs. (30 Nm).
     

  4.  
  5. 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
     

  6.  
  7. Install or connect the following:
    NOTE
    Check 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).
     

  8.  
  9. 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
     

  10.  
  11. Install or connect the following:

    Fuel return pipe
     
    Intake chamber stay. Tighten the bolts to 14 ft. lbs. (20 Nm).
     

  12.  
  13. 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
     

  14.  
  15. 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
     

  16.  
  17. 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
     

  18.  
  19. 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
     

  20.  
  21. Refill the cooling system.
  22.  
  23. Start the engine and check for leaks.
  24.  
  25. Check the ignition timing. Road test the vehicle for proper operation.
  26.  
  27. Recheck all fluid levels.
  28.  

5vz-FE Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Drain the engine coolant.
  8.  
  9. 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
     

  10.  

To install:

  1. Clean all surfaces.
  2.  
  3. 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
     

  4.  
  5. Fill with engine coolant.
  6.  
  7. 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
     

  8.  
  9. Fill the radiator with engine coolant.
  10.  
  11. Start the engine and check for leaks.
  12.  

 
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