Lexus 17101-20070 Intake Manifold

Unplug the battery and drain fuel pressure from the system. Open up the engine from below by removing the oil filler cap and hose clamp, then loosening the three screws around it. To remove the upper intake manifold, which gives you access to the rear valve cover, sensors, and back cylinder head, first get rid of the top cowl/vent cover, windshield wipers, and wiper motor, and then strip off the lower cowl cover afterward. Disconnect the PCV hose from the valve cover. To get the spark plugs out, take off the ground wire, everything from the ACIS system, electrical plugs, and vacuum tubes from the upper part of the intake system, and write down all connections for easy reinstallation. Undo all mounting nuts at the throttle body, loosen all upper intake manifold braces, and lift intake to release from throttle body and lower intake. For other work, take the following off the upper intake manifold/throttle body assembly: disconnect the ground strap, ACIS system components, electrical connectors, vacuum lines, and coolant bypass hoses, and cap off coolant hoses to stop leaks. Uncover the cabin's air filter rack, pull apart the vehicle's air inlet hoses, sever the throttle's electrical connection to its body, and take off the frame bar interfacing the headlights with the front suspension. Take off both brackets from the upper intake manifold (brace), and the throttle body brace. Raise the upper intake manifold/throttle body combination from the engine area. Before starting work on the fuel rail, gather fresh containers to store the drained coolant and set aside the fuel injectors' electrical wires. Remove the fuel line connecting the rail. Take off the heater hoses from the bottom of the intake manifold, undo the mounting bolts and nuts in the opposite order they were tightened, and remove the bottom intake from the engine while avoiding putting force between the gasket contact areas. If the intake manifold is taken off, swap the hose that sends water between the parts. To install the lower intake properly, first you'll need to scrape off and replace the old gasket material and sealant from the cylinder heads and manifold, clean everything, and put in fresh gaskets. You'll then want to make sure the manifold fits tightly on the engine before adding the nuts and bolts. After applying the gasket, carefully tighten nuts and bolts in three or four careful steps, reinstall everything backward from how you took it apart, refill coolant, start the engine, and look for fuel, vacuum, and liquid seeping out.

To remove the intake manifold, first relieve the fuel system pressure and disconnect the cable from the negative battery terminal. Next, remove the air intake duct and resonator, followed by the cowl cover assembly. Then, take out the fuel rail and injectors as an assembly. For models from 1999 to 2007, remove the throttle linkage and throttle body from the intake manifold, label and detach the PCV and vacuum hoses connected to the intake manifold, and securely support the vehicle on jackstands. If working on a 4WD model, loosen the right side driveaxle/hub nut and the right front wheel lug nuts before raising the vehicle. Drain the transfer case lubricant, remove the right side driveaxle, and separate the transfer case mount from the transfer case, removing the transfer case mounting brace. For all models, work below the vehicle to remove the manifold lower mounting bolts, then from above, remove the intake manifold upper mounting nuts and bolts, and take out the manifold, gasket, and manifold insulator from the engine. For models from 2008 and later, remove the engine cover, disconnect the vacuum hoses and ventilation tubes from the intake manifold, and remove the throttle body with the electronic throttle actuator. Additionally, remove the windshield wiper motor, brake booster vacuum bracket, and outer cowl top assembly, then disconnect and remove the main harness connector to the intake manifold and tumble control valves. Apply battery voltage to the tumble control valve electrical connector to close the valve, preventing damage during removal. Remove the intake manifold support bracket and disconnect the vacuum switching valve assembly electrical connector, then unscrew the intake manifold mounting fasteners and remove the manifold. For installation, clean the mating surfaces of the intake manifold and cylinder head mounting surface, checking the gasket for leaks and the manifold for warpage. Press a new gasket into the grooves on the intake manifold, install the manifold and gasket over the studs on the cylinder head, and tighten the manifold-to-cylinder head nuts/bolts in three or four equal steps from the center outwards. Reinstall the remaining parts in reverse order, check the coolant level, refill the transfer case for 4WD models, and ensure the throttle linkage operates smoothly before starting the engine to 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.

Press a new gasket into the grooves on the intake manifold. Install the manifold and gasket over the studs on the cylinder head.