Lexus Car ES, IS, LS 1998-06

Intake Manifold

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Removal & Installation



1uz-FE & 3uz-FE Engines


Click image to see an enlarged view

Fig. Exploded view of the intake manifold mounting and related components-4.0L (1UZ-FE) and 4.3L (3UZ-FE) Engines

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Coolant
     
    Accelerator cable
     
    Throttle and accelerator pedal position electrical connectors
     
    Throttle motor electrical connector
     
    Vacuum Switching Valve (VSV) electrical connectors
     
    Injector electrical connectors
     
    Noise filter electrical connector
     
    Brake booster vacuum hose from the intake manifold
     
    Positive Crankcase Ventilation (PCV) hose from the left-hand valve cover
     
    Evaporative Emission (EVAP) hoses and label for installation
     
    Power steering air hose from the intake manifold
     
    Coolant hoses from the throttle body
     
    2 EVAP-to-intake manifold mounting bolts
     
    Accelerator cable bracket
     
    3 V-bank cover brackets
     
    EVAP VSV
     
    Fuel supply and return lines
     
    6 bolts and 4 nuts, then the intake manifold assembly
     

  6.  
  7. Clean the gasket mating surfaces of old gasket and sealant.
  8.  

To install:

  1. Install or connect the following:

    2 intake manifold gaskets on the cylinder heads with the white painted mark facing upward.
     
    Intake manifold assembly and uniformly, tighten the mounting bolts to 13 ft. lbs. (18 Nm).
     

  2.  
  3. The remaining steps of the installation procedure are the reverse of the removal, while keeping in mind the following items:

    Tighten the V-bank cover brackets to 66 inch lbs. (8 Nm).
     
    Tighten the accelerator cable bracket mounting bolts to 13 ft. lbs. (18 Nm).
     
    Tighten the EVAP VSV to 13 ft. lbs. (18 Nm).
     
    All remaining components.
     
    Coolant
     
    Negative battery cable
     

  4.  

1uz-FE Engine


Click image to see an enlarged view

Fig. Exploded view of the intake manifold mounting and related components-4.0L (1UZ-FE) and 4.3L (3UZ-FE) Engines

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Coolant
     
    Accelerator cable
     
    Throttle and accelerator pedal position electrical connectors
     
    Throttle motor electrical connector
     
    Vacuum Switching Valve (VSV) electrical connectors
     
    Injector electrical connectors
     
    Noise filter electrical connector
     
    Brake booster vacuum hose from the intake manifold
     
    Positive Crankcase Ventilation (PCV) hose from the left-hand valve cover
     
    Evaporative Emission (EVAP) hoses and label for installation
     
    Power steering air hose from the intake manifold
     
    Coolant hoses from the throttle body
     
    2 EVAP-to-intake manifold mounting bolts
     
    Accelerator cable bracket
     
    3 V-bank cover brackets
     
    EVAP VSV
     
    Fuel supply and return lines
     
    6 bolts and 4 nuts, then the intake manifold assembly
     

  6.  
  7. Clean the gasket mating surfaces of old gasket and sealant.
  8.  

To install:

  1. Install or connect the following:

    2 intake manifold gaskets on the cylinder heads with the white painted mark facing upward.
     
    Intake manifold assembly and uniformly, tighten the mounting bolts to 13 ft. lbs. (18 Nm).
     

  2.  
  3. The remaining steps of the installation procedure are the reverse of the removal, while keeping in mind the following items:

    Tighten the V-bank cover brackets to 66 inch lbs. (8 Nm).
     
    Tighten the accelerator cable bracket mounting bolts to 13 ft. lbs. (18 Nm).
     
    Tighten the EVAP VSV to 13 ft. lbs. (18 Nm).
     
    All remaining components.
     
    Coolant
     
    Negative battery cable
     

  4.  

2gr-Fse Engine


Click image to see an enlarged view

Fig. Exploded view of the intake manifold mounting and related components-3.5L (2GR-FSE) engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable. Wait at least 90 seconds before performing any other work.
     
    Coolant
     
    Cool air intake duct seal
     
    Left and right engine room side covers
     
    V-bank cover
     
    Left and right front upper fender protectors
     
    Left and right roof drip side finish mouldings using a moulding removal tool
     
    Front wiper arm head cap
     
    Left and right windshield wiper arm and blade assemblies
     
    Cowl top ventilator louver assembly
     
    No. 2 ventilation hose
     
    Air cleaner cap with air cleaner hose
     
    Throttle body assembly
     

  6.  
  7. Remove intake air surge tank as follows:
    1. Disconnect the vacuum hose from the intake air surge tank.
    2.  
    3. Remove the bolt and disconnect the No. 1 vacuum switching valve assembly from the intake air surge tank.
    4.  
    5. Disconnect the ventilation hose, union to check valve hose and water by-pass hose from the surge tank.
    6.  
    7. Disconnect the 4 wire harness clamps from the intake air surge tank.
    8.  
    9. Remove the bolt and water hose joint from the intake air surge tank.
    10.  
    11. Remove the bolt and disconnect the surge tank stay.
    12.  
    13. Using a 5mm hexagon socket wrench, remove the 6 bolts, 2 nuts and gasket.
    14.  

  8.  
  9. Remove intake manifold as follows:
    1. Disconnect the fuel tube from the delivery pipe sub-assembly.
    2.  
    3. Disconnect the 4 connectors.
    4.  
    5. Remove the 4 bolts, 4 nuts, intake manifold and gasket.
    6.  

  10.  

To install:

  1. Place new gaskets onto the intake manifold and position the intake manifold between the cylinder heads. Tighten the nuts and bolts to 15 ft. lbs. (21 Nm).
  2.  
  3. Install or connect the following:

    4 connectors
     
    Fuel tube to the delivery pipe sub-assembly
     

  4.  
  5. Install the intake air surge tank as follows:
    1. Install a new gasket to the intake air surge tank.
    2.  
    3. Install the intake air surge tank with the 2 nuts. Torque the 2 nuts to 12 ft. lbs. (16 Nm).
    4.  
    5. Using a 5mm hexagon socket wrench, install the 6 bolts. Torque the bolts to 13 ft. lbs. (18 Nm).
    6.  
    7. Install the surge tank stay to the intake air surge tank. Torque the bolt to 15 ft. lbs. (21 Nm).
    8.  
    9. Connect the water hose joint with the bolt and torque to 7 ft. lbs. (10 Nm).
    10.  
    11. Connect the 4 wire harness clamps to the intake air surge tank.
    12.  
    13. Connect the ventilation hose, union to check valve hose and water by-pass hose to the intake air surge tank.
    14.  
    15. Connect the No. 1 vacuum switching valve assembly to the intake air surge tank. Torque the bolt to 13 ft. lbs. (18 Nm).
    16.  
    17. Connect the vacuum hose to the intake air surge tank.

      New gasket and throttle body assembly. Torque the 4 bolts to 7 ft. lbs. (10 Nm)
       
      Air cleaner cap with air cleaner hose
       
      No. 2 ventilation hose
       
      Cowl top ventilator louver assembly
       
      Left and right windshield wiper arm and blade assemblies
       
      Front wiper arm head cap
       
      Left and right roof drip side finish mouldings
       
      Left and right front upper fender protectors
       
      V-bank cover
       
      Left and right engine room side covers
       
      Cool air intake duct seal
       
      Negative battery cable
       

    18.  

  6.  
  7. Refill the cooling system. Start the engine and check for leaks and proper operation.
  8.  
  9. Check the function of the throttle body unit
  10.  
  11. System initialization
  12.  

2jz-GE Engine


Click image to see an enlarged view

Fig. Exploded view of the intake manifold mounting and related components-3.0L (2JZ-GE) engine

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Coolant
     
    Spark plug wires at the spark plugs
     
    Spark plugs
     
    Distributor with the spark plug leads attached.
     
    Radiator
     
    Water pump pulley
     
    Timing belt
     
    No. 2 front exhaust pipe
     
    2 Oxygen (O 2 ) sensor leads
     
    4 nuts, and the manifold heat shield
     
    Exhaust manifolds.
     
    Water bypass outlet and the No. 1 bypass pipe. Remove the 3 O-rings.
     
    Water outlet
     
    No. 1 bypass hose
     
    Vacuum Control Valve (VCV) set and the No. 2 vacuum pipe
     
    Fuel return hose from the oil dipstick guide, remove the mounting bolt and pull the guide and dipstick from the pan. Plug the hole.
     
    Air intake chamber
     
    Fuel delivery pipe, then pull out the injectors.
     
    No. 1 and 2 fuel pipes
     
    Engine harness from the intake manifold
     
    Intake manifold stay
     
    Loosen the 6 bolts and 2 nuts, then lift out the intake manifold.
     

  4.  

To install:

  1. Install or connect the following:

    Install the intake manifold, with a new gasket, and tighten the bolts and nuts to 15 ft. lbs. (21 Nm).
     
    Mounting stay and tighten the bolts to 29 ft. lbs. (39 Nm).
     
    Engine harness to the manifold
     
    2 fuel pipes and tighten the bolts to 78 inch lbs. (9 Nm)
     
    Delivery pipe and injectors. Tighten the pipe bolts to 15 ft. lbs. (21 Nm).
     
    Air intake chamber and tighten it to 15 ft. lbs. (21 Nm).
     
    2 stays and tighten them to 13 ft. lbs. (18 Nm); The No. 1 stay is marked with an F and the No. 2 stay is marked with an R .
     
    The oil dipstick and guide, using a new O-ring
     
    VCV set and the vacuum pipe. Tighten the set mounting bolts to 15 ft. lbs. (21 Nm).
     
    Water bypass outlet and the pipe, tighten the bolts to 78 inch lbs. (9 Nm).
     
    Exhaust manifolds. Tighten the bolts to 29 ft. lbs. (39 Nm).
     
    Heat shield and tighten it to 13 ft. lbs. (18 Nm).
     
    No. 2 front pipe
     
    Timing belt
     
    Radiator and water pump pulley
     
    Distributor and spark plugs
     
    Plug wires to the plugs
     
    Coolant
     
    Negative battery cable
     

  2.  



Click image to see an enlarged view

Fig. Exploded view of the intake manifold mounting and related components-3.0L (2JZ-GE) engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Coolant
     
    Spark plug wires at the spark plugs
     
    Spark plugs
     
    Radiator
     
    Water pump pulley
     
    Timing belt
     
    No. 2 front exhaust pipe
     
    2 Oxygen (O 2 ) sensor leads
     
    4 nuts, and the manifold heat shield
     
    Exhaust manifolds
     
    Water bypass outlet and the No. 1 bypass pipe. Remove the 3 O-rings.
     
    Water outlet
     
    No. 1 bypass hose
     
    Vacuum Control Valve (VCV) set and the No. 2 vacuum pipe
     
    Fuel return hose from the oil dipstick guide; remove the mounting bolt and pull the guide and dipstick from the pan. Plug the hole.
     
    Air intake chamber
     
    Fuel delivery pipe, then pull out the injectors
     
    No. 1 and 2 fuel pipes
     
    Engine harness from the intake manifold
     
    Intake manifold stay
     
    Loosen the 6 bolts and 2 nuts, then lift out the intake manifold
     

  4.  

To install:

  1. Install or connect the following:

    Install the intake manifold, with a new gasket, and tighten the bolts and nuts to 21 ft. lbs. (28 Nm)
     
    Mounting stay and tighten the bolts to 29 ft. lbs. (39 Nm)
     
    Engine harness to the manifold
     
    2 fuel pipes and tighten the bolts to 78 inch lbs. (9 Nm)
     
    Delivery pipe and injectors. Tighten the pipe bolts to 15 ft. lbs. (21 Nm).
     
    Air intake chamber and tighten it to 15 ft. lbs. (21 Nm)
     
    2 stays and tighten them to 13 ft. lbs. (18 Nm); The No. 1 stay is marked with an F and the No. 2 stay is marked with an R .
     
    The oil dipstick and guide, using a new O-ring
     
    VCV set and the vacuum pipe. Tighten the set mounting bolts to 15 ft. lbs. (21 Nm).
     
    Water bypass outlet and the pipe, tighten the bolts to 78 inch lbs. (9 Nm)
     
    Exhaust manifolds. Tighten the bolts to 30 ft. lbs. (40 Nm).
     
    Heat shield and tighten it to 13 ft. lbs. (18 Nm)
     
    No. 2 front pipe
     
    Timing belt
     
    Radiator and water pump pulley
     
    Plug wires to the plugs
     
    Coolant
     
    Negative battery cable
     

  2.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Mark each wire, connector or hose, as it is removed, for proper reinstallation reference.



    Negative battery cable
     
    Engine under cover
     
    Engine coolant
     
    Engine cover
     
    Air cleaner assembly
     
    Throttle body assembly
     
    Water bypass pipe running through intake manifold
     
    Engine and transmission dipsticks and tubes
     
    Air intake chamber
     
    Drive belt
     
    Vacuum control valve set
     
    Power steering pump from mounting (Do NOT disconnect hoses)
     
    Engine wiring, and hoses, as need for access to intake manifold
     



    Fuel pressure pulsation damper
     

  4.  
  5. Disconnect the starter wire from the intake manifold stay. Remove the manifold stay.
  6.  
  7. Remove 7 bolts and 2 nuts and remove the intake manifold and delivery pipe and gasket.
  8.  

To install:

  1. Position a new gasket and the intake manifold and delivery pipe assembly into position.
  2.  
  3. Install the 7 bolts and 2 nuts; torque to 21 ft. lbs. (28 Nm).
  4.  
  5. Insert the water bypass hose between the No. 2 and No. 3 intake ports of the manifold and delivery pipe.
  6.  
  7. Install the manifold stay and torque the bolts to 30 ft. lbs. (40 Nm).
  8.  
  9. Reconnect the starter wire to the manifold stay.
  10.  
  11. Reinstall the remaining components in reverse of the removal procedure.
  12.  

3.0L (1MZ-FE) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Coolant
     
    Throttle/accelerator cable from the throttle body
     
    Air cleaner hose at the air intake chamber and remove it
     
    All lines and hoses. Tag them for installation.
     
    Idle Speed Control (ISC) valve and the throttle body
     
    Exhaust Gas Recirculation (EGR) valve and vacuum modulator
     
    Cylinder head rear plate
     
    Intake chamber stays, any wires, then, the air intake chamber
     
    Fuel injection delivery pipe and the injectors
     
    Water outlet and the bypass outlet
     
    2 bolts and the No. 2 idler pulley bracket stay
     
    8 bolts and 4 nuts, then lift out the intake manifold
     

  4.  

To install:

  1. Thoroughly clean the intake manifold and cylinder head surfaces. Using a machinist's straight edge and a feeler gauge, check the surface of the intake manifold for warpage. If the warpage is greater than 0.0039 in. (0.10mm), replace the intake manifold.
  2.  
  3. Place new gaskets onto the intake manifold and position the intake manifold between the cylinder heads. Tighten the nuts and bolts to 13 ft. lbs. (18 Nm). Tighten the No. 2 pulley bracket bolts to 13 ft. lbs. (18 Nm).
  4.  
  5. Install or connect the following:

    Water bypass outlet and tighten the bolts to 74 inch lbs. (8.3 Nm). Tighten the water outlet to 74 inch lbs. (8 Nm).
     
    Injectors and delivery pipe
     
    Air intake chamber and tighten the 2 bolts and 2 nuts to 32 ft. lbs. (43 Nm); use an 8mm hex wrench
     
    Chamber stays and tighten the mounting bolts to 29 ft. lbs. (39 Nm)
     
    Remaining components. Tighten the emission control valve set to 73 inch lbs. (8 Nm).
     
    All hoses
     
    Accelerator cable, if equipped with automatic transaxle
     
    Coolant
     
    Negative battery cable
     

  6.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Coolant
     
    Throttle/accelerator cable from the throttle body
     
    Air cleaner hose at the air intake chamber and remove it
     
    All lines and hoses. Tag them for installation.
     
    Idle Speed Control (ISC) valve and the throttle body.
     
    Exhaust Gas Recirculation (EGR) valve and vacuum modulator
     
    Distributor
     
    Cylinder head rear plate
     
    Intake chamber stays, any wires, then, the air intake chamber
     
    Fuel injection delivery pipe and the injectors.
     
    Water outlet and the bypass outlet.
     
    2 bolts and the No. 2 idler pulley bracket stay.
     
    8 bolts and 4 nuts, then lift out the intake manifold.
     

  4.  

To install:

  1. Thoroughly clean the intake manifold and cylinder head surfaces. Using a machinist's straight edge and a feeler gauge, check the surface of the intake manifold for warpage. If the warpage is greater than 0.0039 in. (0.10mm), replace the intake manifold.
  2.  
  3. Place new gaskets onto the intake manifold and position the intake manifold between the cylinder heads. Tighten the nuts and bolts to 13 ft. lbs. (18 Nm). Tighten the No. 2 pulley bracket bolts to 13 ft. lbs. (18 Nm).
  4.  
  5. Install or connect the following:

    Water bypass outlet and tighten the bolts to 74 inch lbs. (8.3 Nm). Tighten the water outlet to 74 inch lbs. (8 Nm).
     
    Injectors and delivery pipe.
     
    Air intake chamber and tighten the 2 bolts and 2 nuts to 32 ft. lbs. (43 Nm); use an 8mm hex wrench.
     
    Chamber stays and tighten the mounting bolts to 29 ft. lbs. (39 Nm).
     
    Remaining components. Tighten the emission control valve set to 73 inch lbs. (8 Nm).
     
    All hoses.
     
    Accelerator cable, if equipped with automatic transaxle
     
    Coolant
     
    Negative battery cable
     

  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Coolant
     
    Throttle/accelerator cable from the throttle body
     
    Air cleaner hose at the air intake chamber and remove it
     
    All lines and hoses. Tag them for installation.
     
    Idle Speed Control (ISC) valve and the throttle body
     
    Exhaust Gas Recirculation (EGR) valve and vacuum modulator
     
    Cylinder head rear plate
     
    Intake chamber stays, any wires, then, the air intake chamber
     
    Fuel injection delivery pipe and the injectors
     
    Water outlet and the bypass outlet
     
    2 bolts and the No. 2 idler pulley bracket stay
     
    8 bolts and 4 nuts, then lift out the intake manifold
     

  4.  

To install:

  1. Thoroughly clean the intake manifold and cylinder head surfaces. Using a machinist's straight edge and a feeler gauge, check the surface of the intake manifold for warpage. If the warpage is greater than 0.0039 in. (0.10mm), replace the intake manifold.
  2.  
  3. Place new gaskets onto the intake manifold and position the intake manifold between the cylinder heads. Tighten the nuts and bolts to 11 ft. lbs. (17 Nm). Tighten the No. 2 pulley bracket bolts to 13 ft. lbs. (18 Nm).
  4.  
  5. Install or connect the following:

    Water bypass outlet and tighten the bolts to 74 inch lbs. (8.3 Nm). Tighten the water outlet to 74 inch lbs. (8 Nm).
     
    Injectors and delivery pipe
     
    Air intake chamber and tighten the 2 bolts and 2 nuts to 32 ft. lbs. (43 Nm); use an 8mm hex wrench
     
    Chamber stays and tighten the mounting bolts to 29 ft. lbs. (39 Nm)
     
    Remaining components. Tighten the emission control valve set to 73 inch lbs. (8 Nm).
     
    All hoses
     
    Accelerator cable, if equipped with automatic transaxle
     
    Coolant
     
    Negative battery cable
     

  6.  

3.7L & 4.7L Engines
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Drain the cooling system.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner assembly
     
    Accelerator cable
     
    Cruise control cable
     
    Manifold Absolute Pressure (MAP) sensor connector
     
    Intake Air Temperature (IAT) sensor connector
     
    Throttle Position (TP) sensor connector
     
    Idle Air Control (IAC) valve connector
     
    Engine Coolant Temperature (ECT) sensor
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    Canister purge vacuum line
     
    Brake booster vacuum line
     
    Cruise control servo hose
     
    Accessory drive belt
     
    Alternator
     
    A/C compressor
     
    Engine ground straps
     
    Ignition coil towers
     
    Oil dipstick tube
     
    Fuel line
     
    Fuel supply manifold
     
    Throttle body and mounting bracket
     
    Cowl seal
     
    Right engine lifting stud
     
    Intake manifold. Remove the fasteners in reverse of the tightening sequence.
     

  8.  

To install:

Click image to see an enlarged view

Fig. Intake manifold torque sequence-3.7 & 4.7L engines

  1. Install or connect the following:

    Intake manifold using new gaskets. Torque the bolts, in sequence, to 105 inch lbs. (12 Nm).
     
    Right engine lifting stud
     
    Cowl seal
     
    Throttle body and mounting bracket
     
    Fuel supply manifold
     
    Fuel line
     
    Oil dipstick tube
     
    Ignition coil towers
     
    Engine ground straps
     
    A/C compressor
     
    Alternator
     
    Accessory drive belt
     
    Cruise control servo hose
     
    Brake booster vacuum line
     
    Canister purge vacuum line
     
    PCV valve and hose
     
    ECT sensor
     
    IAC valve connector
     
    TP sensor connector
     
    IAT sensor connector
     
    MAP sensor connector
     
    Cruise control cable
     
    Accelerator cable
     
    Air cleaner assembly
     
    Negative battery cable
     

  2.  
  3. Fill and bleed the cooling system.
  4.  
  5. Start the engine, check for leaks and repair if necessary.
  6.  

3MZ-FE Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable. Wait at least 90 seconds before performing any other work
     
    Oil pan protector
     
    Engine undercover
     
    Coolant
     
    Battery clamp cover
     
    Air cleaner inlet
     
    Lower radiator air deflector
     
    RF wheel
     
    V bank cover by removing the bolt and 2 cap nuts
     
    Air cleaner and intake air connector assembly
     
    Emission control valve
     
    Air intake surge tank
     
    Engine stabilizer control rod
     
    Fuel pipe
     
    Heater inlet water hose
     
    Battery ground cable form the engine
     
    6 fuel injector connectors
     
    Remove intake bolts following the proper sequence as shown.
     


    Click image to see an enlarged view

    Fig. Intake bolt removal sequence-3.3L (3MZ-FE) Engine

    Water outlet
     
    Radiator reserve tank pipe
     
    Upper radiator hose
     
    Engine coolant temp sensor
     
    Water outlet housing
     
    Knock sensor
     
    Gently remove the intake manifold
     

  6.  

To install:

  1. Install or connect the following:

    Two knock sensors and wiring connectors Torque to: 14 ft. lbs (20 Nm)
     

  2.  
  3. Install water outlet
    1. Install 2 new gaskets to the cylinder heads
    2.  
    3. Install water outlet with water by-pass hose
    4.  
    5. Tighten 2 bolts, 2 nuts and 2 washers to 11 ft. lbs. (15 Nm)
    6.  
    7. Connect engine temperature connector
    8.  
    9. Connect radiator reserve tank connector
    10.  
    11. Radiator hose
    12.  

  4.  
  5. Install Intake Manifold
  6.  
  7. Install or connect the following:

    9 bolts, 2 nuts and 2 washers; torque to 11 ft. lbs. (15 Nm)
     

  8.  


NOTE
Using several steps, tighten the bolts and nuts uniformly in sequence



Click image to see an enlarged view

Fig. Intake manifold tightening sequence-3.3L (3MZ-FE) Engine



Retighten 9 bolts and 2 nuts to 11 ft. lbs. (15 Nm)
 
Fuel pipe making sure the connector is seated until it clicks.
 

  1. Install or connect the following:

    Engine stabilizing control rod; torque bolt -A- to 17 ft. lbs. (23 Nm) and bolt -B- to 47 ft. lbs. (64 Nm)
     


    Click image to see an enlarged view

    Fig. Tightening procedure for Engine Stabilizing Rod -3.3L (3MZ-FE) Engine

    Intake air surge tank
     
    Emission control valve set
     
    Air Cleaner assembly
     
    Vacuum hoses
     
    Battery negative wire
     
    Front center suspension upper brace
     
    Engine coolant
     
    V-bank cover sub-assembly
     

  2.  
  3. Run engine and check for coolant and fuel leaks
  4.  
  5. System initialization
  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable. Wait at least 90 seconds before performing any other work
     
    Oil pan protector
     
    Engine undercover
     
    Coolant
     
    Battery clamp cover
     
    Air cleaner inlet
     
    Lower radiator air deflector
     
    RF wheel
     
    V bank cover by removing the bolt and 2 cap nuts
     
    Air cleaner and intake air connector assembly
     
    Emission control valve
     
    Air intake surge tank
     
    Engine stabilizer control rod
     
    Fuel pipe
     
    Heater inlet water hose
     
    Battery ground cable form the engine
     
    6 fuel injector connectors
     
    Remove intake bolts following the proper sequence as shown.

    Click image to see an enlarged view

    Fig. Intake bolt removal sequence-3.3L (3MZ-FE) Engine

     
    Water outlet
     
    Radiator reserve tank pipe
     
    Upper radiator hose
     
    Engine coolant temp sensor
     
    Water outlet housing
     
    Knock sensor
     
    Gently remove the intake manifold
     

  6.  

To install:

  1. Install or connect the following:

    Two knock sensors and wiring connectors Torque to: 14 ft. lbs (20 Nm)
     

  2.  
  3. Install water outlet
    1. Install 2 new gaskets to the cylinder heads
    2.  
    3. Install water outlet with water by-pass hose
    4.  
    5. Tighten 2 bolts, 2 nuts and 2 washers to 11 ft. lbs. (15 Nm)
    6.  
    7. Connect engine temperature connector
    8.  
    9. Connect radiator reserve tank connector
    10.  
    11. Radiator hose
    12.  

  4.  
  5. Install intake manifold
  6.  
  7. Install or connect the following:
    NOTE
    Using several steps, tighten the bolts and nuts uniformly in sequence



    9 bolts, 2 nuts and 2 washers; torque to 11 ft. lbs. (15 Nm)
     



    Click image to see an enlarged view

    Fig. Intake manifold tightening sequence-3.3L (3MZ-FE) Engine



    Retighten 9 bolts and 2 nuts to 11 ft. lbs. (15 Nm)
     
    Fuel pipe making sure the connector is seated until it clicks.
     

  8.  
  9. Install or connect the following:

    Engine stabilizing control rod; torque bolt -A- to 17 ft. lbs. (23 Nm) and bolt -B- to 47 ft. lbs. (64 Nm)

    Click image to see an enlarged view

    Fig. Tightening procedure for Engine Stabilizing Rod -3.3L (3MZ-FE) Engine

     
    Intake air surge tank
     
    Emission control valve set
     
    Air Cleaner assembly
     
    Vacuum hoses
     
    Battery negative wire
     
    Front center suspension upper brace
     
    Engine coolant
     
    V-bank cover sub-assembly
     

  10.  
  11. Run engine and check for coolant and fuel leaks
  12.  
  13. System initialization
  14.  

3uz-FE Engine


Click image to see an enlarged view

Fig. Exploded view of the intake manifold mounting and related components-4.3L (3UZ-FE) Engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Engine under cover
     
    Coolant
     
    V-bank cover
     
    Air cleaner assembly and connectors
     
    Throttle body assembly
     

  6.  
  7. Disconnect the fuel inlet hose (rear fuel pipe) from the fuel main tube.
  8.  
  9. Remove and disconnect the following:

    VSV connector for EVAP
     
    EVAP hose from VSV
     
    VSV from upper intake manifold
     
    4 V-bank cover brackets
     
    Engine wiring protector (LH side) from the upper intake manifold and camshaft bearing cap
     
    2 wire clamps (RH side) from the brackets on the delivery pipe
     
    Engine wire protector (rear side) from the rear water bypass joint and the RH cylinder head
     
    VSV connector for the ACIS
     
    8 injector connectors
     

  10.  
  11. Remove the 6 bolts and 4 nuts and remove the upper and lower intake manifold assembly.
  12.  
  13. If necessary, the upper intake manifold can be disassembled from the lower intake manifold by removing or disconnecting the following:

    Vacuum hose for VSV from air control valve actuator
     
    Vacuum tank hose from lower intake manifold
     
    Vacuum hose (VSV for ACIS) from clamp
     
    Wire clamp from lower intake manifold
     
    Vacuum tank and VSV assembly from ACIS
     
    Air control valve actuator
     
    15 bolts and 5 nuts to remove upper intake manifold from lower intake manifold
     

  14.  

To install:


NOTE
Always be sure to use new gaskets at each component mounting.

  1. Reassemble the upper and lower intake manifold in reverse of disassembly procedure given. Torque the upper intake manifold-to-lower manifold bolts and nuts to 13 ft. lbs. (18 Nm).
  2.  
  3. Install the vacuum tank and VSV assembly. Torque the nuts to 13 ft. lbs. (18 Nm).
  4.  
  5. Reconnect all of the wiring connectors, clamps and vacuum hoses in reverse of the removal procedure.
  6.  
  7. With new gaskets on the cylinder heads (white marks facing outward), position the upper and lower intake manifold assembly into position. Install the 6 bolts and 4 nuts and torque them to 13 ft. lbs. (18 Nm).
  8.  
  9. Reinstall and reconnect all remaining components in reverse of the removal procedure.
  10.  
  11. Refill the cooling system. Start the engine and check for leaks and proper operation.
  12.  

4.0L Engine
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Drain the cooling system.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner assembly
     
    Accessory drive belt
     
    Power steering pump and brackets, if equipped
     
    Fuel line
     
    Fuel injector connectors
     
    Fuel supply manifold and injectors
     
    Accelerator cable
     
    Cruise control cable, if equipped
     
    Transmission cable, if equipped
     
    Throttle Position (TP) sensor connector
     
    Idle Air Control (IAC) valve connector
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Intake Air Temperature (IAT) sensor connector
     
    Heated Oxygen (HO 2 S) sensor connector
     
    Closed Crankcase Ventilation (CCV) system
     
    Manifold Absolute Pressure (MAP) sensor vacuum line
     
    Brake booster vacuum line
     
    Exhaust front pipe
     
    Intake and exhaust manifolds and discard the gaskets
     

  8.  

To install:

  1. Install or connect the following:

    New gasket over the locating dowels
     
    Exhaust manifold to the studs and tighten the nuts finger-tight

    Click image to see an enlarged view

    Fig. Manifold torque sequence-2002-04 4.0L engine

     

  2.  
  3. Install the intake manifold. Torque the fasteners in sequence as follows:
    1. Step 1: Fasteners 1-5 to 30 ft. lbs. (41 Nm).
    2.  
    3. Step 2: Fasteners 6 and 7 to 23 ft. lbs. (31 Nm).
    4.  
    5. Step 3: Fasteners 8-11 to 24 ft. lbs. (33 Nm)
    6.  

  4.  
  5. Install or connect the following:

    Exhaust front pipe
     
    Brake booster vacuum line
     
    MAP sensor vacuum line
     
    CCV system
     
    HO 2 S sensor connector
     
    IAT sensor connector
     
    ECT sensor connector
     
    IAC valve connector
     
    TP sensor connector
     
    Transmission cable, if equipped
     
    Cruise control cable, if equipped
     
    Accelerator cable
     
    Fuel supply manifold and injectors
     
    Fuel injector connectors
     
    Fuel line
     
    Power steering pump and brackets, if equipped
     
    Accessory drive belt
     
    Air cleaner assembly
     
    Negative battery cable
     

  6.  
  7. Fill and bleed the cooling system.
  8.  
  9. Start the engine, check for leaks and repair if necessary.
  10.  

4gr-Fse Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable. Wait at least 90 seconds before performing any other work.
     
    Coolant
     
    Cool air intake duct seal
     
    Left and right engine room side covers
     
    V-bank cover
     
    Left and right front upper fender protectors
     
    Left and right roof drip side finish mouldings using a moulding removal tool
     
    Front wiper arm head cap
     
    Left and right windshield wiper arm and blade assemblies
     
    Cowl top ventilator louver assembly
     
    No. 2 ventilation hose
     
    Air cleaner cap with air cleaner hose
     
    Throttle body assembly
     
    Cold start injector
     

  6.  
  7. Remove intake air surge tank as follows:
    1. Disconnect the vacuum hose from the intake air surge tank.
    2.  
    3. Remove the bolt and disconnect the No. 1 vacuum switching valve assembly from the intake air surge tank.
    4.  
    5. Disconnect the wire harness and hose from the surge tank.
    6.  
    7. Disconnect the ventilation hose from the intake air surge tank.
    8.  
    9. Remove the bolt and water hose joint from the intake air surge tank.
    10.  
    11. Remove the bolt and disconnect the surge tank stay.
    12.  
    13. Using a 5mm hexagon socket wrench, remove the 7 bolts, 2 nuts and gasket.
    14.  

  8.  
  9. Remove intake manifold as follows:
    1. Disconnect the connector for the SCV.
    2.  
    3. Disconnect the SCV position sensor connector.
    4.  
    5. Remove the 4 bolts, 4 nuts, intake manifold and gasket.
    6.  

  10.  

To install:

  1. Place new gaskets onto the intake manifold and position the intake manifold between the cylinder heads. Tighten the nuts and bolts to 15 ft. lbs. (21 Nm).
  2.  
  3. Install or connect the following:

    SCV position sensor connector
     
    DC motor connector for the SCV
     

  4.  
  5. Install the intake air surge tank as follows:
    1. Install a new gasket to the intake air surge tank.
    2.  
    3. Using a 5mm hexagon socket wrench, install the 6 bolts. Torque all bolts, except A, to 13 ft. lbs. (18 Nm).
    4.  
    5. Install the bolt and 2 nuts to the intake air surge tank. Torque bolt A to 15 ft. lbs. (21 Nm) and the nuts to 12 ft. lbs. (16 Nm).
    6.  
    7. Install the surge tank stay to the intake air surge tank. Torque the bolt to 15 ft. lbs. (21 Nm).
    8.  
    9. Connect the water hose joint with the bolt and torque to 7 ft. lbs. (10 Nm).
    10.  
    11. Connect the ventilation hose to the intake air surge tank.
    12.  
    13. Connect the wire harness and hose to the intake air surge tank.
    14.  
    15. Connect the No. 1 vacuum switching valve assembly to the intake air surge tank. Torque the fasteners to 13 ft. lbs. (18 Nm).
    16.  
    17. Connect the vacuum hose to the intake air surge tank.

      Click image to see an enlarged view

      Fig. Intake air surge tank mounting bolt locations-2.5L (4GR-FSE) engine



      Cold start injector. Torque the bolts to 7 ft. lbs. (10 Nm).
       
      New gasket and throttle body assembly. Torque the 4 bolts to 7 ft. lbs. (10 Nm)
       
      Air cleaner cap with air cleaner hose
       
      No. 2 ventilation hose
       
      Cowl top ventilator louver assembly
       
      Left and right windshield wiper arm and blade assemblies
       
      Front wiper arm head cap
       
      Left and right roof drip side finish mouldings
       
      Left and right front upper fender protectors
       
      V-bank cover
       
      Left and right engine room side covers
       
      Cool air intake duct seal
       
      Negative battery cable
       

    18.  

  6.  
  7. Refill the cooling system. Start the engine and check for leaks and proper operation.
  8.  
  9. Check the function of the throttle body unit
  10.  
  11. System initialization
  12.  

 
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