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

I'm posting this up under it's own thread to hopefully get this info spread out a little bit more.

Yesterday I had this ACIS (Acoustic Control Induction System) failure occur on my truck, and fortunately, I was able to find some info about this happening because a friend had actually had it happen to him.

Im curious to see how common this is going to be, as I saw at least 5 or 6 other people with this exact issue in another thread.

Basically what happened to me was I was going to merge onto the highway, I stepped on it to get on the highway, and after 4 grand, it started to miss a bit, then instantly went into limp mode. Pulled over, turned it off.

When I restarted it it was fine....which was odd....it then drove perfectly normal....until I stepped on the gas and it revved up high again

It started missing and went into limp mode....this time throwing a CEL for PO303, cylinder 3 misfire.

I swapped #1 and #3 coil packs, and then drove it again.

After a bit, it did it again, went into limp mode and threw a PO303 cylinder 3 misfire.

Obviously that eliminated the possibility it was the coil. I remembered a friend of mine had a very similar issue with his Tacoma. His did what mine is did,ran fine at lower rpms, and broke up above 4k..went into limp mode.

He told me to pulled the intake....and lo & behold....the same problem he had. The ACIS intake flap snapped off and was bouncing around the intake manifold, most likely plugging #3 intake runner under full throttle, causing the misfire.

After some digging around on here, I found this thread and that this is becoming a more common issue, with everyone here all having the same broken ACIS plenum flap....and the only fix is to replace the entire upper manifold/plenum.

The intake manifold part number is 17190-0P101 and I got mine through McGeorge Toyota for around $600 shipped.

 

Yep, happened to me (my truck). About 19K accrued mileage or so and a 2018 at that. It's infuriating. Especially when the Stealership has no clue and you have to tell them to specifically check it. Thank Gawd for this forum and it's breadth of knowledge about these trucks.

https://www.tacomaworld.com/threads/2016-tacoma-in-limp-mode-fixed.659782/page-3#post-26830846

 

Your thread is actually the one I found that helped confirm my issue, along with what my one friend had gone through and told me about.....so thank you for making one of very few sources of info about this issue. That's why I decided to spread this around as much as I can too. Hopefully someone else can benefit from it.

Yeah, this forum has proven to be a life (and money) saver for a second time for me.

 

Thank you for sharing . Subbed for future reference .
So this thing breaks eventually when flooring the pedal rpms reaching 4t suddenly like someone kicks a door open and the hinges break. Maybe Toyota replace this with aluminum . Anyway thank you again for sharing

 

Not sure why the shaft breaks. Either the ACIS actuator mechanism is not clocked properly when installed, or the door itself is hitting a hard stop excessively at the end of it's full range of motion, subsequently snapping the shaft in half after repeated articulation with full throttle.

 

@ColoradoTJ , hoping you might add this to your helpful thread “2GR-FKS Engine Problem/Failure” . This will be of great resource for us 3rd gen owners as we all know it’s a hit or miss at the dealership . They seldom do real troubleshooting anymore. Thanks.

 

Glad to hear it's an easy fix but rather annoying that it even needed to be done.

 

Yeah, it's one of them stupid little failures that acts like a catastrophic engine failure, lol.....and has proven to be hard to diagnose for dealers.

 

I'll add my experience there too!

 

After experiencing the symptoms this causes....Im wondering that myself. For such a small part, it certainly made the truck act like it was blown up.

 

"Seldom do real troubleshooting anymore"

Categorically false, most of the time we're looking for problems that the customer poorly described and playing detective at the same time. Sure some guys are lazy and some service writers are sleazy, but at the end of the day, a customers bad review hurts the dealership in the eyes of Toyota, so it's worth it to us to actually do diagnostic work.

That being said

I wouldn't have known about this issue if it weren't for this forum.

 

Oh, I'm not complaining it was $600. I'm HAPPY it's only $600! I honestly thought it dropped a valve after I moved coils and the misfire stayed the same.

I will gladly pay $600 all day for an intake manifold instead of $6000 for a new motor.

 

Bummer you had it happen to you - as some have posted it is and has been a brewing issue - more like a design failure and manufacturing failure on Toyota's part. I took mine off when I installed a Magnuson Supercharger - it along with the upper and lower intake are sitting in a box never to be used again unless I sell them. Fortunately the removal and install of those parts is simple. Glad you got it taken care of and shared part numbers with others so they may not be further taken for a ride by their local stealer. FYI - the ACIS is electronically actuated by the ECU around 3500 rpm when under load.

 

Realistically speaking, wouldn't the new intake you replaced will end up having the same issue again? Manufacturer defect?

I wonder if you can just remove the broken flap and throw on new gaskets and sent it...

 

my understanding is this engine is used on other models. does anyone know if this issue occurs on other models, or just the tacoma? if just the tacoma, why?

 

Unfortunately, it's a possibility.

Also unfortunately, you cannot access the flap if it's intact. The back plate that retains the flap is plastic welded/melted into place on the manifold, so its non serviceable. The only option is to replace the whole manifold.

 

ACIS activates as lower as 2600rpms. I've see it activating even lower.
Nothing to do with flooring