Toyota 4Runner 2001-06

Intake Manifold

Print

Removal & Installation



1gr-FE Engine

The 4.0L (1GR-FE) Engine uses a two-piece intake manifold. The upper part (Toyota calls it an Intake Air Surge Tank) mounts the throttle body. The lower intake manifold bolts to the cylinder heads and hold the fuel rails and injectors.

Click image to see an enlarged view

Fig. Upper intake manifold (intake air surge tank) and related parts-4.0L (1GR-FE) Engine



Click image to see an enlarged view

Fig. Lower intake manifold assembly and related parts-4.0L (1GR-FE) Engine

  1. Drain the cooling system.
  2.  
  3. Remove the engine appearance cover.
  4.  
  5. Remove the air intake assembly.
  6.  
  7. Remove the alternator.
  8.  
  9. Remove the power steering pump mounting bolts. Hang the pump securely from the engine without disconnecting the lines.
  10.  
  11. Remove the A/C compressor mounting bolts. Hang the compressor securely from the engine without disconnecting the lines.
  12.  
  13. Disconnect the fuel supply and return hoses.
  14.  
  15. Remove the water inlet and outlet hoses.
  16.  
  17. Remove the water bypass hoses.
  18.  
  19. Remove the fuel vapor hose.
  20.  
  21. Remove the vent hose.
  22.  
  23. Disconnect the 2 VSV connectors.
  24.  
  25. Disconnect the wiring at the throttle body.
  26.  
  27. Remove the throttle body bracket.
  28.  
  29. Remove the oil baffle plate
  30.  
  31. Remove the upper manifold supports (stays).
  32.  
  33. Remove the 2 nuts and 4 bolts and lift off the upper manifold. Discard the gasket.
  34.  
  35. Disconnect the fuel injectors.
  36.  
  37. Remove the intake manifold brace (stay).
  38.  
  39. Remove the 10 bolts and lift off the intake manifold. Discard the gaskets.
  40.  

To install:

  1. Set a new intake manifold gasket on each cylinder head.
    NOTE
    Align the port holes of the gasket and the cylinder head. Note the installation direction of the gasket.

  2.  
  3. Install the intake manifold on the cylinder head. There is no torque sequence for the intake manifold bolts. Torque them evenly and in several passes, to 21 ft. lbs. (28 Nm).
  4.  
  5. The remainder of installation is the reverse of removal.
  6.  
  7. Observe the following torques:

    Intake manifold brace to 30 ft. lbs. (40 Nm).
     
    Upper intake manifold (surge tank) nuts and bolts: 21 ft. lbs. (28 Nm)
     
    Throttle body: 15 ft. lbs. (21 Nm)
     
    Engine appearance cover: 66 inch lbs. (7.5 Nm)
     

  8.  
  9. Refill the cooling system to the correct level.
  10.  
  11. Start the engine and check for leaks.
  12.  

2UZ-FE Engine

The 4.7L (2UZ-FE) Engine uses a two-piece intake manifold. The upper part mounts the throttle body. The lower intake manifold bolts to the cylinder heads and hold the fuel rails and injectors. Note that on this engine, the starter motor is mounted to the lower intake manifold, facing to the rear, engaging the flywheel at the top.

Click image to see an enlarged view

Fig. Upper and lower intake manifolds and related components-4.7L (2UZ-FE) Engine


CAUTION
Fuel injected engine systems remain under pressure after the engine has been turned OFF . Properly relieve the fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Relieve the fuel pressure. For additional information, please refer to the following topic(s): -Fuel System,- -Relieving Fuel System Pressure.-
  2.  
  3. Drain the coolant.
  4.  
  5. Disconnect the fuel lines.
  6.  
  7. Detach the following connectors from the intake manifolds:

    Throttle Position (TP) sensor
     
    Accelerator pedal position sensor connector
     
    Throttle control motor connector
     
    EVAP control connector
     
    Eight fuel injector connectors (tag first)
     
    Engine Coolant Temperature (ECT) sensor and water temperature sender gauge connections
     
    Eight ignition coil connectors (tag first)
     
    Two heated oxygen sensor connectors
     

  8.  
  9. Tag for identification and detach the following hoses from the intake manifolds.

    Vacuum hose from the fuel pressure regulator
     
    PCV hose from the PCV valve on the left side head
     
    Three EVAP hoses
     
    Power steering vacuum hoses from the intake manifold
     
    If not equipped with a hydraulic brake booster system, disconnect the brake booster vacuum tube
     

  10.  
  11. Disconnect the accelerator cable from the throttle body and remove the wire clamps.
  12.  
  13. Disconnect the water bypass hose from the front water bypass joint.
  14.  
  15. Disconnect the engine wiring harness retainers where it attaches to the right side fuel rail.
  16.  
  17. Remove the three bolts holding the engine wiring harness protector from the rear water bypass joint, on both cylinder heads.
  18.  
  19. Remove the ground cables from both cylinder heads.
  20.  
  21. Remove the Diagnostic Connector (DLC1) from the throttle body cover bracket and remove the bracket from the intake manifold.
  22.  
  23. Remove the two nuts and the accelerator cable bracket from the intake manifold.
  24.  
  25. Remove the nuts and bolts and carefully lift off the upper and lower intake manifolds and the fuel rails as an assembly.
  26.  
  27. If required, remove the nuts and bolts and separate the upper and lower intake manifolds.
  28.  

To install:

  1. Clean all parts well. Check the sealing surfaces of the intake manifold parts. Using a precision straightedge and feeler gauge, check all of the sealing surfaces for warping. Maximum distortion allowed is 0.0059 inch (0.15mm). If the distortion is greater than this, the manifolds may not seal properly. The parts should be replaced.
  2.  
  3. Inspect the new gaskets. Factory-type gaskets should have a white painted mark to indicate facing upward. Use care to align the port hole of the gasket and cylinder head. Using two new gaskets on the cylinder heads, carefully lower the intake manifold assembly into place on the cylinder heads. Torque the nuts and bolts to 13 ft. lbs. (18 Nm).
  4.  
  5. Install the throttle body cover bracket and connect the Diagnostic Connector to its bracket.
  6.  
  7. Connect the wiring, hoses and cables, using the identification tags made at removal. Verify that the fuel line connections are secure and that the fuel injector connectors are installed on the proper injector.
  8.  
  9. Install the air intake assembly.
  10.  
  11. Refill with coolant to the correct level. Test run the engine and check for coolant and vacuum leaks.
  12.  

5vz-FE Engine


Click image to see an enlarged view

Fig. Upper and lower intake manifold and related parts-3.4L engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove the engine under-cover.
  8.  
  9. Drain the cooling system.
  10.  
  11. Remove or disconnect the following:

    Air cleaner cap
     
    Mass Air Flow (MAF) meter and the resonator
     
    Actuator cable with the bracket, if equipped with cruise control
     
    Accelerator cable
     
    Throttle cable, if equipped with automatic transmission
     

  12.  
  13. Disconnect the following hoses:

    Heater hose
     
    Brake booster vacuum hose
     
    Evaporative Emissions (EVAP) hose
     
    Automatic Disconnecting Differential (ADD) vacuum hose, for 4-wheel drive
     
    Fuel inlet and fuel return hose
     

  14.  
  15. Remove or disconnect the following:

    Spark plug wires, with the ignition coils
     
    Intake chamber stay
     
    No. 2 timing belt cover
     
    Air intake chamber assembly
     
    Throttle Position (TP) sensor connector
     
    Idle Air Control (IAC) valve connector
     
    Positive Crankcase Ventilation (PCV) hoses
     
    Water bypass hoses
     
    Air assist hose from the throttle body
     
    Intake air connector
     
    Engine wiring harness
     
    Fuel return hose
     
    Vacuum hose, from the fuel pressure regulator
     
    Ground strap, from the intake air connector
     
    Data Link Connector 1 (DLC1), from the bracket
     
    6 injector connectors
     
    Engine Coolant Temperature (ECT) sensor and sender gauge connectors
     
    Engine wiring harness protector from the cylinder head
     
    Fuel pressure regulator
     
    Intake manifold assembly
     
    Intake manifold stay
     
    Intake manifold, delivery pipes and the injectors assembly with the gaskets
     

  16.  


    Click image to see an enlarged view

    Fig. Intake manifold bolts and nuts-3.4L engine


To install:

  1. Install or connect the following:

    New gaskets
     
    Intake manifold assembly. Tighten the bolts and nuts to 13 ft. lbs. (18 Nm).
     
    Intake manifold stay. Tighten the bolts to 14 ft. lbs. (18 Nm).
     
    Fuel pressure regulator
     
    Engine wiring harness to the cylinder head, by installing the 3 bolts
     
    3 engine wiring harness clamps
     
    6 injector connectors
     
    ECT sender gauge connector
     
    ECT sensor connector
     
    Intake manifold. Tighten the bolts and nuts to 14 ft. lbs. (18.5 Nm).
     
    DLC1 to the bracket on the intake manifold
     
    Ground strap to the intake manifold, by installing the bolt
     
    Brake booster vacuum hose, to the intake air connector
     
    2 fuel return hoses
     
    Engine wiring harness to the intake manifold
     
    Air intake chamber assembly to the engine. Tighten the bolts and nuts to 14 ft. lbs. (18.5 Nm).
     
    Intake chamber stay. Tighten the bolts to 30 ft. lbs. (40 Nm).
     
    New O-ring to the oil filler tube
     
    Oil filler tube end into the tube hole in the oil pan
     
    Oil filler tube and No. 1 throttle cable clamp
     
    No. 2 timing belt cover. Tighten the bolts to 80 inch lbs. (9 Nm).
     
    PCV hoses
     
    Water bypass hoses
     
    Air assist hose to the throttle body
     
    IAC valve connector
     
    TP sensor connector
     
    Brake booster vacuum hose
     
    EVAP hose
     
    Automatic Disconnecting Differential (ADD) vacuum hose, for 4-wheel drive
     
    Fuel inlet and fuel return hose
     
    3 spark plug wire clamps to the No. 2 timing belt cover
     
    CMP connector to the No. 2 timing belt cover
     
    Spark plug wires with the ignition coils
     
    Heater hose
     
    Actuator cable with the bracket, if equipped with cruise control
     
    Accelerator cable
     
    Throttle cable, if equipped with automatic transmission
     
    MAF meter, resonator and the air cleaner cap
     
    Negative battery cable
     

  2.  
  3. Fill the radiator with engine coolant.
  4.  
  5. Start the engine and check for leaks.
  6.  
  7. Install the engine undercover.
  8.  
  9. Road test the vehicle.
  10.  
  11. Recheck all fluid levels.
  12.  



Click image to see an enlarged view

Fig. Use a ratchet to remove the upper intake manifold bolts-3.4L (5VZ-FE) Engine



Click image to see an enlarged view

Fig. Once all the fasteners have been removed, lift off the upper intake manifold-3.4L (5VZ-FE) Engine



Click image to see an enlarged view

Fig. View of the upper intake manifold and its bolt locations-3.4L (5VZ-FE) Engine



Click image to see an enlarged view

Fig. Remove the upper intake manifold gasket from the lower intake runners-3.4L (5VZ-FE) Engine



Click image to see an enlarged view

Fig. The upper intake manifold gasket may be made from several steel shims riveted together-3.4L (5VZ-FE) Engine



Click image to see an enlarged view

Fig. Remove the middle-to-lower intake manifold bolts-3.4L (5VZ-FE) Engine



Click image to see an enlarged view

Fig. Once all fasteners have been removed from the middle intake manifold, lift it off the lower intake manifold-3.4L (5VZ-FE) Engine



Click image to see an enlarged view

Fig. Inspecting the intake manifold gasket for cracks or deterioration-3.4L (5VZ-FE) Engine



Click image to see an enlarged view

Fig. Stuff shop towels into the intake runners to prevent dirt and debris from entering the engine-3.4L (5VZ-FE) Engine



Click image to see an enlarged view

Fig. View of the middle intake runners-3.4L (5VZ-FE) Engine



Click image to see an enlarged view

Fig. View of the lower intake manifold after it has been removed from the vehicle-3.4L (5VZ-FE) Engine

The 3.4L (5VZ-FE) Engine uses what could be called a three-piece intake manifold. The upper part (Toyota calls it an air intake chamber assembly) mounts the throttle body. The middle part is called an intake air connector assembly, jointing the air intake chamber with the lower manifold. The lower part is considered the actual intake manifold, bolts to the engine and mounts the fuel injectors. Toyota uses aluminum for many engine parts. Use care when working with light alloy parts as they are easily damaged.

Click image to see an enlarged view

Fig. Exploded view of the upper and lower intake manifolds- 3.4L (5VZ-FE) Engine



Click image to see an enlarged view

Fig. Mounting bolt locations on the upper, middle and lower portions of the intake manifolds-3.4L (5VZ-FE) Engine

  1. Relieve the fuel system pressure. For additional information, please refer to the following topic(s): -Fuel System,- -Relieving Fuel System Pressure.-
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the engine coolant.
  6.  
  7. Remove the air cleaner hose.
  8.  
  9. Disconnect the following cables:

    On cruise control vehicles, the actuator cable with bracket
     
    Accelerator cable
     

  10.  
  11. Tag for identification, then disconnect the two hoses from the air intake chamber assembly and the EVAP hose.
  12.  
  13. Disconnect the fuel return and fuel feed hoses.
  14.  
  15. Remove the upper intake manifold (air chamber) brace (Toyota calls it a stay). Remove the two bolts holding the throttle cable clamp, and then remove the two bolts holding the brace.
  16.  
  17. Remove the No. 2 timing belt cover. This is the cover that goes over the cam belt sprockets. It will be necessary to disconnect the four spark plug cable clamps that run across the top of the cover. Then remove the six retaining bolts and carefully separate the cover from the engine. Look for the wire from the Camshaft Position Sensor and detach the connector, if required.
  18.  
  19. At the upper intake manifold (air intake chamber), disconnect the following:

    Throttle Position (TP) sensor connector
     
    Idle Air Control (IAC) connector
     
    Accelerator pedal position sensor connector
     
    Two PCV hoses
     
    Two water bypass hoses
     

  20.  
  21. Remove the nuts and bolts holding the upper intake manifold (air intake chamber) assembly. Discard the gasket.
  22.  
  23. Remove the middle part of the intake manifold assembly (air connector) by unbolting the engine ground wire, disconnecting the fuel return hose, if not done so already, and the vacuum line to the fuel pressure regulator. Detach the Diagnostic Connector (DLC1) from the bracket. Remove the nuts and bolts and separate the middle part of the intake manifold. Discard the gasket.
  24.  
  25. Locate the engine wiring harness protector. Detach the six fuel injector connectors, the Engine Coolant Temperature (ECT) sensor connector(s) and unbolt the wiring harness protector assembly from the cylinder head.
  26.  
  27. Disconnect the fuel pressure regulator.
  28.  
  29. Remove the nuts and bolts from the lower part of the intake manifold and carefully work the manifold free of the cylinder heads. Discard the gasket.
  30.  

To install:

  1. Clean all parts well. Pay particular attention to the gasket sealing surfaces. Use care not to damage the light alloy parts.
  2.  
  3. Installation is the reverse of the removal process. Always use new gaskets. Carefully place the lower part of the intake manifold to the cylinder heads. Make sure all flat washers, nuts, and bolts are installed. Tighten to 13 ft. lbs. (18 Nm), working from the center fasteners, outward.
  4.  
  5. Install the engine wiring harness protector and attach all removed connectors.
  6.  
  7. Using a new gasket, install the middle part of the intake manifold (air connector). Install the nuts and bolts and tighten to 13 ft. lbs. (18 Nm), working from the center fasteners, outward.
  8.  
  9. Place the Diagnostic Connector (DLC1) back on its bracket. Connect the engine ground wire and all of the vacuum hoses detached at removal, using the identification tags made earlier.
  10.  
  11. Using a new gasket, install the upper part of the intake manifold (air chamber). Install the nuts and bolts and tighten to 13 ft. lbs. (18 Nm), working from the center fasteners, outward.
  12.  
  13. Connect all remaining wires, hoses and cables, as required.
  14.  
  15. Install the timing belt cover and air cleaner hose.
  16.  
  17. Refill the engine with fresh coolant.
  18.  
  19. Start the engine and check for coolant and vacuum leaks.
  20.  

 
label.common.footer.alt.autozoneLogo