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

Bummer this is happening to some folks. It kind of looks like the rubber gasket would be prone to folding over and causing undue stress or partially jamming itself. I used to have a 2006 Dodge Charger with the 3.5L in it. That had a similar butterfly system they called the Short Runner valve. Similar to fiber reinforced plastic and molded into the plenum just like this. Didnt have any gaskets but over time all the recirculated crankcase gases caused the butterfly to get very sticky. It would throw a CEL once in a while because the actuator couldnt turn it.

 

I wonder if this is partially addressed with the various tunes out there

 

I'm pretty sure the OTT tune for 2nd gens opens the ACIS flap/valve lower/earlier in rpm band than stock.

I know this is a 3rd-gen thread but I wonder if this failure occurs in 2nd gens also, or if instead this part has been signifcantly re-engineered or "value engineered" in the 3rd gen 3.5V6...

 

When 3rd gen tune was developed, acis was left at oem setting. Per OVT, there was no gain to move it around. I'm sure it can be tuned up and down

 

So today I got my new intake, and replaced it. Afterwards I decided to cut open the old intake to look at how it works...and boy...am I glad I did!

I saw a spot for a pivot bushing.....a bushing I had not recovered.

If this happens to anyone else, when you change the intake....you MUST check the intake runners for 1, 3, and 5.

When I cut the old intake apart to scope it out....I immediately saw there was a space for a bushing...and I knew I didn't have it....meaning only one thing ....it was still in the engine.

I pulled the new intake back off....and there it was in intake runner 1....sitting on top of the valve. I used a small piece of safety wire to fish it out and it didn't look like it did damage....but there was a good possibility it could have. I got lucky AF.

Again...if this happens to your truck, and you replace the intake manifold.....I repeat, CHECK THE LOWER INTAKE FOR THIS SPACER.

 

holy shit dude. You're a pro. catching that missing bushing.

 

Thanks! Engine building 101....if you suddenly are missing parts for the top end.....it's most likely inside the engine!
Thank goodness I chose to cut that intake open... otherwise I wouldn't have known there WAS a bushing in there.

 

Great catch, that's some good old fashion wrenching there folks. No part out for you......

 

Great catch and thank you for sharing.

Why did Toyota build the intake like this? Makes no sense at all. Are we all going to have this happen at some point when we're up in the woods or pulling a boat out of the water??

 

Great catch. Thanks for sharing and warning others. Thankfully this failure is still rare. But who knows as time marches on.

 

3rd gens are just starting to get solidly into the aging regime, i.e. the oldest 3rd gen is now just 7 years old. Takes time for fatigue-related wear and/or design defects to manifest, sometimes.

 

All cars are appliances for quite some time now. It's all planned obsolescence coupled with corporate greed. Toyotas and the rest of the OEMs are all quilty of this.

And looks like the bushing is pressed in placed until it's not..jeeze what a shitshow

 

Yep! I said the exact same thing. It's closing in on the time frame for time related issues to start popping up.

 

Yes it is, once that rod breaks and the valve falls out of place, that bushing can just slide out.

 

Bruh. I need to take you fishing with me
How the hell did you get that out??

 

Aviation safety wire. I cut a length about 16" long and bent the end into a 3/8" long "hook". After carefully manipulating the bushing back around the valve stem and in front of it, I slid the hook end into the hole and pulled it out.

 

fckn amazing skill dude. I hope you hit the lottery or some monster size trophy fish holy shat

 

Thanks! It wasnt the first object I've fished out of an engine, and it probably won't be the last.

 

Nice!!!

 

Good catch!

And for you anti catch can people…look how oily that intake is…