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May be applicable to other models too?
I having removed the intercooler and the EGR housing on my 1KZ-TE a couple of times and the inlet manifold once I have a few traps tricks and tips – or else I am going to tell some of you how to suck eggs
1st, one has to realise that the engine is dropped in to the engine bay pretty much all assembled., so some parts are a bathplug to remove.
The intercooler comes of easy peasy but do not lose one of the rubber mounting grommets as unbelievably Toyota do not sell the as a part – they only come with the whole intercooler.
The rear mount is a bugger to get he bolt back in as the bracket it is set on an angle and trying to get the bolt lined up – grrrr. I have read of a few that gave up and simply leave it off.
But my solution is to forget the bolt and put a stud in the bolt hole and fit the intercooler with grommet in place over it then tight down the required size nut.
A lot less frustration
And the EGR manifold inlet housing is a total a bathplug to remove>
The large retainer nut on the inlet pipe?? Probably forget it as after 300k it is well set and, in any case, bloody hard to get a swing at with the huge open ender one needs. If one can get it off, I guess the EGR inlet housing just comes off with the manifold.
The nuts on the 2 studs can be removed but because of the space to the firewall, even with the manifold free the only way I could separate the two was a struggle and I bent one of the EGR studs getting the manifold off.
I’m not sure why the design engineers simply did not use bolts rather than studs
While cleaning the manifold my Kiwi brain came up with a solution for reassembly.
I did think of using the aforementioned bolts but as the manifold thread is a blind housing and ali, I did this
I got 2 studs of the appropriate length – depth of stud housing + 1cm (A) + thickness of EGR housing bolt flange+ at least 1cm.
I then filed flats on the stud within the A 1cm to take a 7 OE spanner.
Put the manifold back on without the EGR studs
Line up the EGR and fiddle to get the studs through and in to the manifold stud thread, as far as you fingers can tighten>
I did the far one first, then
Using getting gap between the 2 faces use the 7mm in and screw in the stud
repeat for the nearer stud.
Push the EGR in to place and simply do up the nuts as usual.
I having removed the intercooler and the EGR housing on my 1KZ-TE a couple of times and the inlet manifold once I have a few traps tricks and tips – or else I am going to tell some of you how to suck eggs
1st, one has to realise that the engine is dropped in to the engine bay pretty much all assembled., so some parts are a bathplug to remove.
The intercooler comes of easy peasy but do not lose one of the rubber mounting grommets as unbelievably Toyota do not sell the as a part – they only come with the whole intercooler.
The rear mount is a bugger to get he bolt back in as the bracket it is set on an angle and trying to get the bolt lined up – grrrr. I have read of a few that gave up and simply leave it off.
But my solution is to forget the bolt and put a stud in the bolt hole and fit the intercooler with grommet in place over it then tight down the required size nut.
A lot less frustration
And the EGR manifold inlet housing is a total a bathplug to remove>
The large retainer nut on the inlet pipe?? Probably forget it as after 300k it is well set and, in any case, bloody hard to get a swing at with the huge open ender one needs. If one can get it off, I guess the EGR inlet housing just comes off with the manifold.
The nuts on the 2 studs can be removed but because of the space to the firewall, even with the manifold free the only way I could separate the two was a struggle and I bent one of the EGR studs getting the manifold off.
I’m not sure why the design engineers simply did not use bolts rather than studs
While cleaning the manifold my Kiwi brain came up with a solution for reassembly.
I did think of using the aforementioned bolts but as the manifold thread is a blind housing and ali, I did this
I got 2 studs of the appropriate length – depth of stud housing + 1cm (A) + thickness of EGR housing bolt flange+ at least 1cm.
I then filed flats on the stud within the A 1cm to take a 7 OE spanner.
Put the manifold back on without the EGR studs
Line up the EGR and fiddle to get the studs through and in to the manifold stud thread, as far as you fingers can tighten>
I did the far one first, then
Using getting gap between the 2 faces use the 7mm in and screw in the stud
repeat for the nearer stud.
Push the EGR in to place and simply do up the nuts as usual.