Intake manifold gasket replacement - please help!

[wallyuwl]

I have the 1ZZ engine and replaced my intake manifold gasket yesterday. It was getting dark so I didn't start it up until today.

Today when I stated it up it barely started, then idled really rough for about thirty seconds, then I shut it off before it died. I started it up a couple more times, each time a bit better, but it would still want to die afte a minute or two.

The weirdest part is the brake pedal is stuck in the up position. No brakes. I've heard it can idle rough until the computer readjusts, but the no brakes thing is how I know something is wrong.

Anyone have any ideas? Everything is hooked up and back in its original position. Used a torque wrench on the bolts with the proper torque on the intake and TB bolts. I did disconnect the coolant lines from the throttle body which could have let air in. Would air in the cooling system cause all these problems?

Any help apprecaited. Really don't want to have to take it to a dealer (via tow truck)...

[Bdub215]

Did you hook up the vacuum line for the brake booster?


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[wallyuwl]

All lines are hooked back up as they were before the repair. It is losing vacuum some how, some where.

[mikered30]

Double check your connections, you must have missed or crossed a line.

[extreme one]

I seemed to recall that in the back of the Intake Manifold there is a hose that is easily missed.

[wallyuwl]

Originally Posted by extreme one

I seemed to recall that in the back of the Intake Manifold there is a hose that is easily missed.

That might have been it. After checking things three or four times and not finding anything disconnected, I got it towed to the dealer (insurance will cover tow). They said a hose was disconnected to the intake. They only charged $49 to check it out, fix the hose, and test drive the vehicle. That is way cheaper than having a mechanic do all the work (I did more than just the intake gasket), and not a bad price IMO to know everything is good.

[Ktt88]

I had the EXACT same problem with my 1zz while replacing my intake manifold gasket. Unfortunately it wasnt as cheap as a $49 for me. Care to share where this hose was? I still dont know and its been bothering me ever since I had it fixed by the dealer.

Thanks!

[wallyuwl]

Originally Posted by Ktt88

I had the EXACT same problem with my 1zz while replacing my intake manifold gasket. Unfortunately it wasnt as cheap as a $49 for me. Care to share where this hose was? I still dont know and its been bothering me ever since I had it fixed by the dealer.

Thanks!

I wish I could help you. I have looked for probably fifteen minutes over several different "trials" and have yet to find what hose could have been disconnected. I can't find any hoses going into the inake that I didn't put back on to begin with. I guess it is possible there is one that got knocked off somewhere that I was unaware of (ie: I didn't disconnect it on purpose, and thus didn't know to put it back).

[wallyuwl]

Originally Posted by Ktt88

I had the EXACT same problem with my 1zz while replacing my intake manifold gasket. Unfortunately it wasnt as cheap as a $49 for me. Care to share where this hose was? I still dont know and its been bothering me ever since I had it fixed by the dealer.

Thanks!

I think I found the hose that might have been disconnected. It is nearly impossible to see with the throttle body on. If you look/feel the coolant hoses on the throttle body (there are two, each about 1/2 in diameter, right next to each other pointing toward the back of the engine compartment), there is a thicker hose to the left that appears to go into the intake manifold. I don't even remember taking this hose off, but either did so and don't remember, or it came off on its own when I moved the manifold after it was unbolted.

[invader]

That hidden vacuum hose goes on the back of intake manifold, beside throttle body by the coolant lines.

[toyman2005]

That's the same hose I almost missed when changing my intake manifold gasket. I only noticed it when I had bolted everything back up before initial start up. It was a tad tough to put back on without removing the throttle body again, but got it back on reaching down with needle nose pliers and carefully sliding it back on. It's the hose that is behind the throttle body to the lower left, facing the rear of the car. Easy to miss!

[invader]

1st pic shows elusive brake booster vacuum hose on intake manifold, which is hidden once throttle body is installed... Intake manifold gasket was easily replaced on friend's 2005 without draining any coolant or disconnecting throttle body coolant lines, by setting (+cleaning) throttle body aside.