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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> Engine Mechanical >> Exhaust >> Engine Intake / Exhaust System (2GR-FKS) - Service Information >> Intake Manifold >> Removal [12/2019 - 10/2022] >> Procedure

Removal [12/2019 - 10/2022]: Procedure

  1. PRECAUTION 
    NOTE:

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

    Refer to PRECAUTION [12/2019 - 11/2023]

  2. DISCHARGE FUEL SYSTEM PRESSURE 

    Refer to PRECAUTION [12/2019 - 10/2022]

  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Refer to PRECAUTION [12/2019 - 11/2023]

  4. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to REMOVAL [12/2019 - ]

  5. REMOVE FENDER SPLASH SHIELD SUB-ASSEMBLY REAR LH 

    Refer to PROCEDURE - Step 3

  6. REMOVE FENDER SPLASH SHIELD SUB-ASSEMBLY REAR RH 

    HINT: 

    Perform the same procedure as for the LH side.

  7. REMOVE FRONT FENDER SPLASH SHIELD SEAL FRONT LH 

    Refer to PROCEDURE - Step 5

  8. REMOVE FRONT FENDER SPLASH SHEILD SEAL FRONT RH 

    HINT: 

    Perform the same procedure as for the LH side.

  9. REMOVE FRONT UPPER SUSPENSION TO COWL BRACE SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 7

  10. REMOVE FRONT UPPER SUSPENSION TO COWL BRACE SUB-ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  11. REMOVE COWL VENTILATOR PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 9

  12. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to REMOVAL [12/2019 - 10/2022]

  13. REMOVE V-BANK COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 23 [12/2019 - 09/2020] , or refer to PROCEDURE - Step 23 [09/2020 - 10/2022]

  14. DISCONNECT VENTILATION HOSE 
    1. Slide the clip and disconnect the ventilation hose from the intake air surge tank assembly.
      GTY936705Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. DISCONNECT PURGE VALVE (PURGE VSV) 
    1. Disconnect the No. 1 fuel vapor feed hose from the intake air surge tank assembly.
      GTY886040Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and disconnect the purge valve (purge VSV) from the intake air surge tank assembly.
  16. REMOVE NO. 2 SURGE TANK STAY 
    1. Remove the 2 bolts and No. 2 surge tank stay from the intake air surge tank assembly and camshaft housing RH.
      GTY886041Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE INTAKE AIR SURGE TANK ASSEMBLY 
    1. Disconnect the No. 1 vacuum switching valve assembly (for ACIS) connector.
      GTY936704Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 2 clamps to disconnect the vacuum hose sub-assembly from the intake air surge tank assembly.
    3. Disengage the 2 clamps to disconnect the vacuum hose sub-assembly from the intake air surge tank assembly.
      GTY907657Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Vacuum Hose Sub-assembly
      *2 Vacuum Hose
      *3 No. 2 Air Tube
    4. Disengage the clamp to disconnect the vacuum hose from the intake air surge tank assembly.
    5. Disengage the clamp to disconnect the No. 2 air tube from the intake air surge tank assembly.
    6. Remove the 5 bolts, 2 nuts and intake air surge tank assembly from the intake manifold.
      GTY886037Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE AIR SURGE TANK TO INTAKE MANIFOLD GASKET 
    1. Remove the air surge tank to intake manifold gasket from the intake air surge tank assembly.
      GTY627987Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE NO. 1 V-BANK COVER BRACKET 

    HINT: 

    Perform this procedure only when replacement of the No. 1 V-bank cover bracket is necessary.

    1. Remove the 2 No. 1 V-bank cover brackets from the intake air surge tank assembly.
      GTY627913Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE NO. 2 ENGINE MOUNTING STAY RH 
    1. Remove the bolt, 2 nuts and No. 2 engine mounting stay RH from the engine mounting insulator sub-assembly RH and rear engine mounting stay RH.
      GTY886033Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE REAR ENGINE MOUNTING STAY RH 
    1. Remove the bolt and disconnect the engine wire from the rear engine mounting stay RH.
      GTY886034Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and rear engine mounting stay RH from the intake manifold.
      GTY886035Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. DISCONNECT FUEL TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  23. REMOVE FUEL DELIVERY PIPE WITH SENSOR ASSEMBLY 

    Refer to PROCEDURE - Step 6

  24. REMOVE NO. 1 DELIVERY PIPE SPACER 

    Refer to PROCEDURE - Step 7

  25. REMOVE INJECTOR VIBRATION INSULATOR 

    Refer to PROCEDURE - Step 8

  26. REMOVE INTAKE MANIFOLD 
    1. Remove the 4 bolts, 4 nuts and intake manifold from the cylinder head sub-assembly.
      GTY886065Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET 
    1. Remove the 2 No. 1 intake manifold to head gaskets from each cylinder head sub-assembly.
      GTY886066Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE STUD BOLT 

    HINT: 

    If a stud bolt is deformed or the threads are damaged, replace it.

    1. Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the intake manifold.
      GTY627992Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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