Lexus 17111-31141 Manifold, Intake

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To remove the intake manifold, start by relieving the fuel system pressure and disconnecting the negative battery terminal. Remove the air intake duct, radiator, and cowl cover assembly. For 2009 and earlier models, remove the fuel rail and injectors, throttle linkage, and throttle body from the intake manifold. Label and detach the PCV and vacuum hoses connected to the rear of the intake manifold. Raise the vehicle and remove the manifold lower mounting bolts. From above, remove the intake manifold upper mounting nuts and bolts, along with the manifold, gasket, and manifold insulator. For 2010 and later models, remove the engine cover, disconnect vacuum hoses and ventilation tubes, and remove the throttle body from the intake manifold. Disconnect the fuel intake line from the fuel rail and disconnect the electrical connectors and harness mounting fasteners. Disconnect and remove the main harness connector from the intake manifold and tumble control valves. Apply battery voltage to the tumble control valve electrical connector to close the valve. Remove the intake manifold support bracket and disconnect the vacuum switching valve assembly electrical connector. Unscrew the intake manifold mounting fasteners and remove the manifold. To install, clean the mating surfaces and check for warpage. Press a new gasket into the grooves on the intake manifold and install it over the studs on the cylinder head. Tighten the manifold-to-cylinder head nuts or bolts in three or four equal steps. Install the remaining parts in reverse order and check for coolant and vacuum leaks.

The upper intake manifold, referred to by Toyota as the intake air surge tank, requires the disconnection of the negative battery terminal, with a warning for 2GR-FKS engines to relieve fuel system pressure beforehand. After removing the engine cover, all hoses and wiring from the throttle body should be disconnected, with coolant hoses pinched off to prevent draining the cooling system and labeled for clarity. The windshield wiper arms, motor, side seals, and plastic cowl must be removed, followed by the throttle body bracket, upper intake manifold brace, and throttle body. Disconnect all wiring and hoses from the upper intake manifold, then remove the mounting fasteners and the manifold itself, checking the gasket for damage and replacing it if necessary. Installation follows the reverse order, ensuring the mounting bolts and nuts are tightened to the specified torque in a circular pattern starting from the inner bolts. For the lower intake manifold, known as the intake manifold, first remove the upper intake manifold. If replacing the lower intake manifold, the fuel rail should be removed, although for 2GR-FE engines, it may not be necessary unless disconnecting fuel supply and return lines. On 2GR-FKS engines, the upper fuel rail must be removed before the lower intake manifold. After removing the interfering brace and engine mount brackets, unscrew the bolts to take off the lower intake manifold, discarding old gaskets and cleaning the mating surfaces thoroughly. Installation is again the reverse of removal, using new gaskets and tightening the bolts in a criss-cross pattern from the center outward to the specified torque.

All wiring and hoses need to be disconnected from the manifold.

1. Remove the engine cover (Lift the cover up from the rear, off the ballstuds, then detach the front, and remove the cover). 2. Disconnect the vacuum hoses and ventilation tubes from the intake manifold. 3. Remove the throttle body with the electronic throttle actuator from the intake manifold. 4. Remove the windshield wiper motor. Remove the brake booster vacuum bracket and the outer cowl top assembly. 5. Disconnect and remove the main harness connector to the intake manifold and tumble control valves. Note: The tumble control valve harness connector is located just below the throttle body. 6. Using test leads, apply battery voltage to terminal no. 8 of the tumble control valve electrical connector and ground the no. 4 terminal. This will close the tumble control valve to prevent it from being damaged when the manifold is removed. Don't apply voltage longer than three seconds. 7. Remove the intake manifold support bracket and disconnect the vacuum switching valve assembly electrical connector. 8. Unscrew the intake manifold mounting fasteners and remove the manifold.

Remove the bolts and nuts mounting the upper intake manifold to the lower intake manifold, then move the upper intake manifold to the side and separate it from the throttle body and lower intake manifold.

The upper direct injection fuel rail must be removed before the lower intake manifold can be removed.

Remove the throttle body mounting nuts.

Remove the air intake duct and resonator, then remove the cowl cover assembly.