How to Replace the Intake Manifold in a Toyota Tacoma

Disconnect the negative battery cable. Drain the cooling system (see Warnings). Remove the air cleaner assembly and hoses from the carburetor.

Label all the vacuum lines from the EGR valve and carburetor and disconnect them. Pull the EGR pipe from the manifold, then remove the valve and the pipe.

Remove the fuel lines, all electrical connections and the accelerator linkage. Take the water hose from the carburetor and disconnect the water bypass hose from the manifold.

Loosen the bolts that hold the intake manifold in place. Remove the bolts and lift out the intake manifold along with the carburetor and EGR valve.

Shake out several clean shop rags. Drape them over the cylinder head ports to prevent debris from falling into the head or the block.

Clean the mating surfaces with compressed air and solvent to remove all gasket material and debris. Examine the surfaces for damage.

Replace the gasket, using the appropriate sealant. Set the manifold in place.

Set the manifold mounting nuts and bolts in place. Tighten them to 14 foot pounds over a series of three passes. Start in the center and work out in a criss-cross pattern.

Connect the bypass line and then reconnect all the other hoses and lines. Replace the air cleaner.

Refill the cooling system. Use the proper amount and type of coolant.

Start the engine. Check for oil or vacuum leaks. Top of any fluid levels as needed.