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Super Moderator
2005 Corolla CE
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14,833 Posts
Discussion Starter #1 (Edited)
Well I am up here in Virginia for a little while and it's been pretty cold. The past few days my idle has been very low and I knew my original intake gasket had run its course (104k is alright with me). So I headed over to Priority Toyota and spent around 7 bucks and change to get an updated orange intake gasket.

The intake gasket failure is very prevalent during the winter months or cold weather in general (I've seen issues happen in the 40's). Toyota issued a TSB for this issue. My DIY differs slightly from the TSB making it easier and not requiring coolant replacement. TSB below:

http://www.toyotapart.com/M.I.L._ON_DTC_P0171,_AND_OR_PO133_ENGINE_RUNNING_LEAN_IN_SUBFREEZING_AMBIENT_TEMPERATURES_T-EG045-07.pdf

This DIY will work for all 2003-2008 models with only a few slightly differences for 2003-2004 models. Those different steps are mostly centered around the throttle body and an extra support bracket between the intake manifold connecting and the throttle body. I have now added the steps for 2003-2004 models into the DIY. I would like to give credit to forum member shatterpulse for his images on the 2003-2004 stuff.

Disclaimer: Myself or ToyotaNation are not responsible for any damage or injury that may result from use of this DIY. All vehicles should be diagnosed and repaired by qualified technicians. Proceed with this DIY at your own risk.


Tools needed

3/8 inch drive ratchet
3/8 inch drive extensions (3 in, 6 in, 9 in)
3/8 inch drive 10mm socket
3/8 inch drive 12mm socket
3/8 inch drive torque wrench (optional I didn't use it)
Rags (new clean rags preferred)
Brake cleaner
Throttle body cleaner (if cleaning throttle body)
2 M6 x 1.0 Bolts to replace the plastic clips securing the engine cover (if needed)

Part numbers

Intake Manifold Gasket:

Toyota - 17171-22060
Victor Reinz - MS19590

Throttle Body Gasket:

Toyota -
2003-2004 Models: 22271-0D030
2005-2008 Models: 22271-0D051

Victor Reinz -
2003-2004 Models: G31655
2005-2008 Models: G32143

FelPro -
2003-2004 Models: 61134
2005-2008 Models: 61421




Here we go!

1. Secure parking brake and then secure hood in open position.



2. Remove the engine cover. Using your 10mm socket and ratchet, remove the 10mm nut, loosen the 10mm stud nut, and remove the two plastic clips if you have them and remove the engine cover.

Note: The two rear plastic clips regularly get lost/break. I replaced mine with two M6x1.0 bolts with a 10mm head. Much nicer.

Note: Occasionally the 10mm nut will come of the valve cover/engine cover stud. However this almost never happens and the nut will loosen the entire stud as a "stud-nut" referred to above..



3. Remove and set aside the air cleaner and hose. Loosen the 10mm hose clamp for the throttle body and remove the PCV breather hose by pulling it straight off. It should come right off, but if it doesn't press the clamp and lower it on the hose and use hose pliers to twist off the hose. Unclip the air box lid and set the air box with PCV and intake hose to the side.



4. Remove the vacuum and breather hoses from the top of the intake manifold by pulling them straight off. They should come right off, but if they don't press the clamp and lower/raise (depending on perspective) it on the hose and use hose pliers to twist off the hose.



5. Remove the electronic throttle body connectors.

2003-2004 models:

Push the center connector release and pull off the connector for both the upper Throttle Position Sensor (TPS) connector and lower Idle Air Control Valve (IACV) connector.



2005-2008 models:

Push the center connector release and pull off the connector for the drive-by-wire (DBW) throttle body assembly.



6. Remove the throttle body.

2003-2004 Models:

Using your 12mm socket and ratchet, remove the two 12mm nuts and two 12mm bolts securing the throttle body to the intake manifold. Then remove the one 12mm bolt securing the lower throttle body bracket to the the lower part of the intake manifold (the other part of the bracket is secured by a lower throttle body bolt). Remove the throttle body support bracket. Finally using your 10mm socket and ratchet remove the two 10mm bolts securing the upper throttle body support bracket to the intake manifold (Manual Transmission Models Only). Remove the lower throttle body support bracket and set it aside. Pull off the throttle body and while routing the cooling lines away from the studs in the intake manifold, hang the throttle body.




2005-2008 Models:

Using your 10mm socket and ratchet, remove the two 10mm nuts and two 10mm bolts and pull off the throttle body. Route the cooling lines away from the studs in the intake manifold and hang the throttle body.



7. Remove the intake manifold wiring harness clip. Using your screwdriver release the catch and remove wiring harness clip from above the alternator.



8. Remove the intake manifold bolts.

2003-2004 models:

Remove the two 12mm bolts on the bracket located on the right side of the intake, two 12mm nuts holding the wiring harness retainers, and two remaining 12mm bolts from the intake manifold. Remember where each bolt/nut came from.

2005-2008 models:

Remove the one 12mm bolt near the bottom of the intake, two 12mm bolts on the bracket located on the right side of the intake, two 12mm nuts holding the wiring harness retainers, and two remaining 12mm bolts from the intake manifold. Remember where each bolt/nut came from.

Caution: Remember the orientation of the small bracket closest to the throttle body. It should go back on the same way it came off and uses two different length bolts to secure it.

Note: The only difference here between 2003-2004 and 2005-2008 models is that the lower bolt has already been removed on 2003-2004 models.



9. Remove the wiring harness from the intake manifold by pulling back the two wiring harness retainers (from around the nuts), flipping them around and moving the wiring harness out of the way.



10. Remove the intake manifold by pulling it back and out off the studs.

Caution: When removing take note of the hidden vacuum line behind the intake and remove it.



11. Remove the factory intake gasket.



This is what caused the whole issue.



12. Using your brake clean and rag clean the face of the intake manifold and cylinder head.




13. Install the new intake gasket. Make sure the indents line up and seat the gasket flush with the manifold.



14. Install the intake manifold on the cylinder head. Reinstall the two wiring harness retainers around the studs, and on the clip above the alternator.

2003-2004 models:

Install the intake manifold on the cylinder head. Reinstall the two wiring harness retainers around the studs, and on the clip above the alternator. Using your 12mm socket and ratchet, install all the 12mm bolts and nuts in their proper locations. Make sure to leave the bolts for the small bracket near the throttle body loose, the bracket installed in the correct orientation, not to install the bolt at the lower part of the intake manifold yet.

2005-2008 models:

Using your 12mm socket and ratchet, install all the 12mm bolts and nuts in their proper locations making sure to reinstall the small bracket near the throttle body in the correct orientation.

Don't forget the hidden vacuum line behind the intake manifold from the removal procedure. Be sure to install it now.

I installed all bolts and nuts hand tight with my ratchet but have done around a bunch and never had an issue. This is my personal car too.



Torque Specs:

12mm bolts - 22 ft lbs.

15. Reinstall the throttle body.

2003-2004 models: Clean the throttle body and reinstall or just reinstall the throttle body. If replacing the throttle body gasket, pull it off and do so now. To install first place the throttle body into position over the studs. Then slip the lower throttle body support bracket over the lower left throttle body stud (closest to the throttle cable). Thread the two 10mm bolts securing the upper throttle body support bracket into the throttle body finger tight. Thread on and tighten the two 12mm nuts and 12mm bolts securing the throttle body to the intake manifold. Tighten the one 12mm bolt securing the throttle body support bracket to the lower intake manifold. Tighten the two 12mm bolts securing the upper throttle body support bracket to the intake manifold. Finally tighten the two 10mm nuts securing the upper throttle body support bracket to the throttle body (Manual Transmission Models Only).

2005-2008 models: Clean the throttle body and reinstall or just reinstall the throttle body. If replacing the throttle body gasket, pull it off and do so now. Using your 10mm socket and ratchet, install the 10mm nuts and bolts. Follow this DIY to clean the throttle body:

http://www.toyotanation.com/forum/132-9th-generation-2003-2008/421382-diy-2005-2008-corolla-matrix-pontiac-vibe-dbw-throttle-body-cleaning-pics.html

Note: Remember to route the cooling hoses around any dipsticks or studs that may get in the way.



Torque Specs:

10mm bolts (Manual Transmission Models Only) - 9.6 ft lbs.
12mm bolts/nuts - 22 ft lbs.

16. Reinstall the two vacuum lines on top of the throttle body.

Note: Make sure the hose retainer clips are in the proper position.

17. Reinstall the air cleaner assembly and PCV breather hose.

Note: Make sure the hose retainer clip is in the proper position.

18. Reinstall the engine cover.

Note: If you lost/broke your clips install your new M6 x 1.0 bolts now.

19. Start the engine and verify you have no vacuum leaks. And it idles properly.

20. Be amazed at your work.

Hope this helps. My car idles like new again.
 

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Super Moderator
2005 Corolla CE
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14,833 Posts
Discussion Starter #4
A clean engine is a happy engine. I clean both all my engines when I wash my cars.
 

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19 Corolla HB SE 6-spd
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5,903 Posts
Yeah, especially before working on it. Sometimes, you have to work in somebody else's dirty engine bay... Very nice DIY, hartopted72.

Also, congratulations on being named a Moderator. Your integrity is truly legendary.
 

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Super Moderator
2005 Corolla CE
Joined
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14,833 Posts
Discussion Starter #6
Yeah, especially before working on it. Sometimes, you have to work in somebody else's dirty engine bay... Very nice DIY, hartopted72.

Also, congratulations on being named a Moderator. Your integrity is trully legendary.
Thanks again (BTW they are taking applications. Just read the sticky at the top of the forum).

And that is very true. When I worked at the dealer, if you purchased my recommendations I would personally wash the car and clean the entire engine bay. Sometimes it would bite me if it was a Sienna or CrewMax Tundra though lol.
 

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George
13 Camry
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33 Posts
Your Post Changing the Intake Gasket

I have to ask you why you did this. I have a P0171 code on my 07 Corolla. One possibility for this code is an air leak around the intake gasket. Is that why you changed it? Were you able to somehow identify an air leak around this gasket?:thanks:
 

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Super Moderator
2005 Corolla CE
Joined
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14,833 Posts
Discussion Starter #8
This defective part will cause a P0171, as well as P0300-304 misfire codes. The gasket melts and leaks causing rough idle and sometimes the above codes.

Mine had a rough idle so I replaced it. Had I let it go longer those codes were sure to come. This is a known issue and I am confident all gaskets will fail at some point.
 

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Registered
2006 Toyota Corlloa
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27 Posts
Great write up! Congrats on the Moderator status! Your knowledge is appreciated on here by all that read.:clap:
 

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Registered
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37 Posts
Great how to...

Having recently been through this on an 03, I can say that the procedure works fine there as well. It's a pretty straight forward job. One caution I would add, is to pay attention to the shiny metal cylindrical inserts between the manifold and the studs (not sure what Toyota calls them; sleeves, spacers?). Make sure all of those metal sleeves are in place on the manifold, before re-fitting the manifold on the studs. In your photos, all of the sleeves stayed in the manifold, when I was swapping manifolds, a couple of the sleeves fell out of the manifold during the swap. If the manifold is reinstalled without all of the sleeves, it could create problems. Very nice writeup and photos. Great addition to the forum. In other forums, I've seen posts like this become "Sticky Threads" or put in some other permanent reference section. Does this forum have something similar?

Never mind, just found the DIY thread. What part of VA were you/are you in? I'm in south central VA. Nice time to visit and enjoy the fall colors.
 

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George
13 Camry
Joined
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33 Posts
Thanks. I read about this gasket in a few places. My car idles fine. I am checking gas mileage now, but my sense is that it is going to be fine. I know the part is cheap and I could do this myself, but I am not ready to believe this is the problem that I have.
 

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Super Moderator
2005 Corolla CE
Joined
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14,833 Posts
Discussion Starter #12
I was in Ft. Lee area. Good note to add. I have done tons of these and never had an insert fall out. But I guess I see the possibility. Good info to add.
 

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Registered
2005 Corolla S
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8 Posts
After 421,000 km's on my '05 S I started getting the P0171 codes. Had the dealer replace the intake gasket and the code went away. This write-up would have saved me some cash, though I don't remember them gouging me too bad for it.
 

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DOHC VTEC
2004 Corolla CE
Joined
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208 Posts
After 421,000 km's on my '05 S I started getting the P0171 codes. Had the dealer replace the intake gasket and the code went away. This write-up would have saved me some cash, though I don't remember them gouging me too bad for it.
This would be my exact thought. If the intake gasket is causing vacuum leak, I would suspect at least a lean code like P0171.
 

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Registered
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437 Posts
I replaced mine with another black gasket. I just replaced it with the same defective part didn't I..fml

Anyway, on a side note, I didn't remove the TB or the connector.

 

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Super Moderator
2005 Corolla CE
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14,833 Posts
Discussion Starter #17
Lol yes you did. Also I guess you don't have to remove the TB but getting a good clean on the surfaces will be harder and I'd rather not pull on the TB harness.

The gasket you got will likely last at least 4-5 years. But the new updated one is 7 bucks give or take. Might just do it again.
 

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DOHC VTEC
2004 Corolla CE
Joined
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208 Posts
I just got mine done like 10 mins ago with the orange gasket. I didn't know about the hidden vacuum hose even though I read this DIY once before. I pulled the IM up as much as I can with the TB still hooked and everything. So the hidden vacuum hose must've fell off it's port when I yanked it out and I got done with the installation, I started her up and car idle like crap, very low idle and seems like it's almost mis-firing. Sprayed with brake cleaner to find the leak, and it's coming from the driverside as the engine idle changes from low to high. Remove everything back out, and noticed that the hidden vacuum hose was unhooked. Anyways, got everything in and car was fine.

My car still idles like around 400rpm in gear. It doesn't misfire or anything, just idles low. I want to know where you guy's sits at with it in "R" or "D".

So far, I cleaned the throttle body blade, made sure there's no carbon build up in the throttle body bore where the blade meets. And changed the IM gasket with the updated one. Still sits at 400rpm at normal operating temp in gear.

I have yet to do plugs even though it's close to 170K miles. I'll be getting the NGK and a new air filter too; since, it seems a bit dirty.
 

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Super Moderator
2005 Corolla CE
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14,833 Posts
Discussion Starter #20
Clean your IAC valve. It is the next most likely culprit and it has probably never been cleaned.

You will have to remove and disassemble it from the throttle body assembly to properly clean it. It takes a while and is tedious.
 
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