[Mk2] [NA] Removing inlet manifold

[Border]

Right, this might seem like a stupid question but here goes.

trying to remove the inlet manifold on my rev2 so i can get to the rocker cover to replace the gasket that's weeping like a mofo. i've undone the two nuts and 6 bolts holding the upper half of the inlet manifold to the TVIS part and i've undone the brackets for the throttle cable etc. what else needs undoing as the little bu88er won't budge at all!
can anyone help?
cheers

[mr2magic]

Just so I understand correctly: You're removing the whole intake manifold just to remove the valve cover?

[Border]

just the part that goes from the throttle body to the TVIS butterflies mate, sorry i wasn't clearer!

[mr2magic]

I still don't quite understand. TVIS is between the head and the manifold. Between TVIS and the throttle body is the manifold. So it still sounds to me like you removing this:



to get at this:

[Border]

Sorry, i'm new to these cars, always been a vw man till now! I have a rev2 NA engine, i thought the TVIS unit was the chamber at the rear of the engine around valve cover height?

if that's not the TVIS bit then sorry for confusing you, basically i want to remove the manifold that sits on top of the rocker cover and goes from the throttle body to the chamber with some sort of vacuum operated actuator on the side of it!

[mr2magic]

Ok, now we're getting somewhere Don't worry about not knowing You'll get to know everything in good time and I certainly wasn't trying to belittle your efforts, I was only trying to find out exactly what you meant

Can you supply a pic of exactly what you mean?

[Border]

i can do tonight, not near the car just now. basically it's the part of the intake system that sits right on top of the rocker cover. looks like it should be simple to remove but it's being a stubborn little sod

[mr2magic]

Wait a sec, you have an N/A so it's a bit different! My bad!

I'm guessing your motor looks something like this:

[Border]

yep that's the one! i need to remove the bit that says toyota on it. i've removed the bolts you can see on the far side of the engine and the brackets on the nearside (in the photo) along with the throttle body but it's still not moving!

[mr2magic]

Super! You now know, that you don't have TVIS The N/A had ACIS.

Ok! According to the BGB you've removed everything necessary. The bracket with 4 screws and the resonance box with 6 screws and two nuts. Does it seem to be sticking in one spot or does the wohloe thing not move?

Don't forget there is a gasket there too. That could be sticking. Give it a tug.

[Border]

Think I'll get the hammer out then for some gentle persuasion!

It moves a couple of millimetres but no more than that which made me think there could be something else attached somewhere, I didn't want to break anything without asking first in case it was something simple.

Thanks for your help mate. Care to explain the difference between TVIS and ACIS briefly too please? I know very little about these engines!

[mr2magic]

Do that! But please note - I'm a Gen2 turbo ninja, n/a is not my strong point

TVIS - Toyota Variable Induction System: Basically a system of buttefly valves on the intake side of the head which block off half of the intake port at low rpm forcing the air to accelerate to fit through the open half and thereby improving VE and torque at low RPM

ACIS - Acoustic Control Induction System: A single butterfly valve which is used to alter the length of the intake runners.

Here you can find an in depth write up on both systems:

http://www.turbomr2.com/MR2/Reference/TVIS/TVIS.htm

[phipck]

i removed mine the other week to do this exact job, but also did remove all the induction to replace all gaskets.

from memory, remove the throttle cable,
then 2 bolts for the bracket with the "s" shaped raised piece (just to the left of the throttle body in the above pic),
then remove the throttle cable bracket one step further to the left,
then the 4 bolts holding the throttle cable guide again one step to the left.
the inlet will no longer be "attached" to the engine top.

continuing, remove the 4 bolts holding the throttle body to the inlet end,
remove the 5 bolts and 2 nuts holding the inlet to the secondary inlet section.

this is all the fixings for the "toyota" labled section of the inlet. i found that holding the labled end of the inlet and gently moving it up and down (too and from the cam cover) slowly seporated the gasket on the join to the second section of inlet. it should slowly come away

then you have all the bolts for the cover what cam gasket kit did you get?

[Border]

cheers lads, don't think i've ever had so much trouble getting something so simple off an engine!

i got a gasket kit from eurocarparts seeing as i've got a mate who works there and i get preferential prices

one more question - what are the torque specs for the rocker cover bolts? they have what look like rubber washers which surprised me a bit, i'm used to seeing everything torqued down on solid surfaces!

[phipck]

from memory because of the rubber washers its ment to be finger tight with a full turn!

but im sure i did something more accurate/little tighter than that

[Slarty]

With regards to the cam cover bolt washers, buy yourself some new ones.

Toyota seem to have slightly revised them (from what I could see!) instead of a flat metal washer over the top of the rubber you now have a metal inner and outer sleave with rubber between them.

This prevents you from over tightening the bolts and snapping the cam cover (as many have done in the past) as all that will happen is the inner sleave pulls down further as the bolt sits on that face rather than the outer. It'll make sense when (if) you see them.

From memory the actual torque figure is really low, somewhere around 1-2lb/ft

10 x T90210-07001 at about 70p each.