3.5 V6 ACIS plenum/manifold flap failure (2GR-FKS) SECOND UPDATE

CGribb · Mar 27, 2025

Gagedakine808 said: ↑

did yours have smoke coming out of exhaust too?
Click to expand...

It didn't have any smoke, and still doesn't. I just installed the new intake last night, and no issues so far with the truck, so it seems to have solved my issue.

Blaketford · Apr 2, 2025

I’ll be checking this Sunday….I’ve been having an issue where after coasting downhill when I get back on the throttle I get a cough of blue smoke after a sputter…I noticed in the picture of bushing on top of the valve that things appeared oily…I hope this is my problem…dealership want 6300 for valve seals and guides….I just don’t believe that’s it…cheers

Blaketford · Apr 9, 2025

220/221... said: ↑

Whelp... chalk up another intake plenum ACIS broken flap "catastrophic failure."
*2017 TRD/OR with 77,000miles*
Driving up an on ramp to merge into freeway traffic, and suddenly have a total loss of acceleration, dash lights up with all the CEL goodies, and truck goes into limp mode. So I take it to the shoulder, turn it off and wait a couple minutes. Start it back up and CEL's disappear and truck is running/idling normal. Start getting up to speed to merge into freeway traffic and about 20-25mph it goes back into limp mode with CEL's, so I pull back to the shoulder. I'm a little stumped because the truck seems to idle fine, but won't drive over 20-ish mph... Tow the truck to my house, log on to this very thread and the "2016 Tacoma in limp mode, FIXED!" thread, and bingo!

Followed the advice here on intake plenum removal (thanks to JohnnyTRD06 !!), opened up the ACIS actuator, and found the worm gear/flap axis to be flopping around and totally disconnected from the rest of the flap still inside the plenum. The flap itself had not yet dropped into the intake, but the end had snapped so the flap was just chilling in "forever-closed" position, starving the intake of air needed at the higher rpm's (but still idling fine). No flap/parts were dumped into my intake valves thankfully (I inspected same carefully).

Incredibly, same day day/locally I was able to find a used low mile (20k) intake plenum with actuator/flap/etc all clean and intact (I opened the actuator cover and checked) for $240.
While I had everything opened up in the engine bay, I replaced the spark plugs, put dielectric grease on the coil packs and other electrical connections, deep-cleaned the throttle body, etc. Reassembled everything, fired it up, took it for a drive last night and all codes are gone... it actually runs noticeably smoother than it did before the ACIS flap failure, likely due to new sparkplugs and cleaned up TB.
If something were to fail down the road with this new plenum, I'll just rip the broken flap out of my old plenum and run that with the flap delete.
>> Anyone have advice on HOW to get the flap out of the plenum?? Mine is still mostly intact in the plenum. It is broken, but not yet loose/rattling around. If I can dislodge it, will it drop out through the throttle body hole or one of the intake ports? <<

I wanted to express my appreciation for this group / this thread... I would have struggle-bussed the crap out of this one had I not found this. Instead, I was down for only 2 days and out $240. Winner, winner.

(I'll offer one small piece of info that I scoured for here but couldn't find super clearly: if for some reason your actuator gears get disassembled and you're trying to ensure assembly gets re-aligned for correct "clocking" of the flap and gears - the 'engine off/plate closed position' is a full counter-clockwise turn of the worm gear... ie: turn worm gear counter-clockwise and flap should be in closed-position, then re-install cover. When it actuates under higher rpm load, it will turn clockwise, opening the pos flap, then back to counter clockwise for closed/low rpms. It's been said in different words but didn't indicate which way the gear should be turned on re-assembly. Minor detail, but might help somebody.)
Click to expand...

Blaketford · Apr 9, 2025

My question regarding clocking the valve before installing the actuator is …turning the flap gear counter clockwise is that as viewed from the rear of the manifold?..or the front….I’d hate to spend 600 bucks after doing it bass ackwards…cheers!!

lgallard101 · Apr 30, 2025 at 10:33 AM

@JohnnyTRD06 Do I need to replace the air surge tank gasket or everyone reused it?

Blaketford · Apr 30, 2025 at 11:38 AM

Reused mine

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3.5 V6 ACIS plenum/manifold flap failure (2GR-FKS) SECOND UPDATE

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