How To Replace Intake Manifold on Toyota Prius?

The procedure to replace Toyota Prius intake manifold.
The Intake manifold replacing details and diagrams.

All this is mentioned here for help.

Intake Manifold
REMOVAL & INSTALLATION Details are as follows:----

  1. Disconnect the negative battery cable. Wait at least 90 seconds after disconnecting the negative battery cable to prevent possible airbag and seat belt pretensioner activation.
  2. Drain the engine coolant.
  3. Remove the air cleaner assembly.
  4. Remove the cylinder head. 

    Fig. Remove/install oil dipstick guide-1.5L hybrid engine
  5. Remove the oil dipstick guide.
  6. On 2002-03 Prius models, remove the throttle body assembly as follows: 

    1. Disconnect the throttle position sensor connector.
    2. Disconnect the throttle control motor connector.
    3. Disconnect the 2 PCV hoses from throttle body.
    4. Disconnect the 2 water by-pass hoses.
    5. Remove the bolt, 2 nuts, accelerator bracket and throttle body from the intake manifold.
    6. Remove the throttle body gasket. 

      Fig. Intake manifold hoses/harnesses to disconnect/connect-1.5L hybrid engine

      Fig. Location of intake manifold mounting bolts and nuts-1.5L hybrid engine
  7. Remove the bolt and knock control sensor with bracket.
  8. Disconnect the wiring harness from the bracket.
  9. Disconnect the ventilation hose.
  10. Disconnect the water by-pass hose.
  11. Remove the 3 bolts and 2 nuts, then remove the intake manifold and gasket.
To install:
  1. Install a new gasket, then install the intake manifold with the bolts, nuts and brackets. Uniformly tighten the bolts and nuts in several passes to 15 ft. lbs. (20 Nm).
  2. Connect the water by-pass hose.
  3. Connect the ventilation hose.
  4. Install the knock control sensor with bracket with the bolt and tighten to 80 inch lbs. (9 Nm).
  5. On 2002-03 Prius models, install the throttle body assembly and tighten the mounting bolt and nuts to 15 ft. lbs. (20 Nm).
  6. Apply engine oil to a new O-ring, then install it to the dipstick guide.
  7. Install the dipstick guide with the bolt and tighten to 80 inch lbs. (9 Nm).
  8. Install the cylinder head.
  9. Install the dipstick.
  10. Install the air cleaner assembly.
  11. Refill the engine coolant.
  12. Connect the negative battery cable.
  13. Start the engine and check for coolant leaks.

These details will help.


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