Toyota Highlander 6 2001-06

Intake Manifold

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Removal & Installation



3.0L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:


  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Drain and recycle the engine coolant.
  8.  
  9. Remove or disconnect the following:
    NOTE
    The delivery pipes with injectors will be attached to the manifold.



    Accelerator cable
     
    Throttle cable
     
    Air cleaner
     
    Any wiring or hoses interfering with removal
     
    Right side engine mount stay
     
    Radiator and heater hoses in the way of the intake manifold removal
     
    V-bank cover
     
    All the vacuum hose and wiring for the emission control valve set
     
    Air intake chamber and discard the gasket
     
    Exhaust Gas Recirculation (EGR) pipe and discard the gaskets
     
    Hydraulic motor pressure hose from the air intake chamber
     
    Engine wiring harnesses from the left side, right side, rear and No. 3 timing belt cover
     
    Front exhaust pipe, if necessary
     
    Timing belt, camshaft timing pulleys, No. 2 idler pulley and No. 3 timing belt cover
     
    Cylinder head rear plate
     
    2 bolts, nuts and plate washers with the intake manifold.
     



    Other fuel related components such as the No. 2 fuel pipe and pulsation damper, if needed
     
    Delivery pipes from the intake manifold
     

  10.  
  11. Clean and inspect the intake manifold mating surfaces. Scrape all old gasket material off.
  12.  

To install:

  1. Install or connect the following:
    NOTE
    Be sure to place 4 spacers in position on the manifold. Temporarily install 4 bolts to retain the delivery pipes to the manifold. Inspect the injectors for smooth rotation.


    NOTE
    Be sure the gasket is in place properly prior to tightening.



    Delivery pipes with injectors to the intake manifold.
     



    Tighten the delivery pipes bolts to 84 inch lbs. (10 Nm), once the injectors are properly seated
     
    No. 2 fuel pipe with union bolts and gaskets. Tighten the bolts to 24 ft. lbs. (32 Nm).
     
    No. 1 fuel pipe with pulsation damper, using 4 new gaskets. Tighten the damper to 35 ft. lbs. (32 Nm) and the bolt to 11 ft. lbs. (15 Nm).
     
    Fuel pressure regulator, if removed
     
    Intake manifold. Tighten the 9 bolts and 2 nuts in a crisscross pattern to 11 ft. lbs. (15 Nm).
     

  2.  
  3. Retighten the water outlet mounting nuts/bolts to 11 ft. lbs. (15 Nm), if loosened.
  4.  
  5. Install or connect the following:

    Air assist hose and water inlet pipe, using a new O-ring, by applying a small amount of soapy water. Tighten the fastener(s) to 14 ft. lbs. (20 Nm).
     
    Ground strap
     
    Vacuum hoses removed to the air intake chamber and vacuum tank
     
    Any remaining components, using new gaskets. Tighten the air intake chamber nuts/bolts to 32 ft. lbs. (43 Nm), the EGR pipe nuts to 108 inch lbs. (12 Nm) and the emission control valve set to 69 inch lbs. (8 Nm).
     
    Air cleaner assembly
     
    Heater hoses
     
    Throttle cable with bracket onto the throttle body
     
    Accelerator cable, by adjusting it, if equipped with an automatic transaxle
     

  6.  
  7. Refill the cooling system
  8.  
  9. Install or connect the following:

    Negative battery cable
     
    Heater air duct
     

  10.  
  11. Start the engine and inspect for leaks.
  12.  

3.3L Engines
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Wiper and blade assembly
     
    Top cowl seal and panel
     
    Window washer hoses from the ventilator louvers
     
    Left and right ventilator louvers
     
    Heater air duct
     
    Front upper suspension brace
     

  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Remove the battery and battery tray.
  8.  
  9. Drain and recycle the engine coolant.
  10.  
  11. Remove or disconnect the following:
    NOTE
    The delivery pipes with injectors will be attached to the manifold.



    Accelerator cable
     
    Throttle cable
     
    Air cleaner cap assembly
     
    Any wiring or hoses interfering with removal
     
    Right side engine mount stay
     
    Radiator and heater hoses in the way of the intake manifold removal
     
    V-bank cover
     
    All the vacuum hose and wiring for the emission control valve set
     
    Air intake chamber and discard the gasket
     
    Exhaust Gas Recirculation (EGR) pipe and discard the gaskets
     
    Hydraulic motor pressure hose from the air intake chamber
     
    Engine wiring harnesses from the left side, right side, rear and No. 3 timing belt cover
     
    Front exhaust pipe, if necessary
     
    Timing belt, camshaft timing pulleys, No. 2 idler pulley and No. 3 timing belt cover
     
    Cylinder head rear plate
     
    2 bolts, nuts and plate washers with the intake manifold.
     



    Other fuel related components such as the No. 2 fuel pipe and pulsation damper, if needed
     
    Delivery pipes from the intake manifold
     

  12.  
  13. Clean and inspect the intake manifold mating surfaces. Scrape all old gasket material off.

    Click image to see an enlarged view

    Fig. Intake manifold and related parts-3.3L engine

  14.  

To install:

  1. Install or connect the following:
    NOTE
    Be sure to place 4 spacers in position on the manifold. Temporarily install 4 bolts to retain the delivery pipes to the manifold. Inspect the injectors for smooth rotation.


    NOTE
    Be sure the gasket is in place properly prior to tightening.



    Delivery pipes with injectors to the intake manifold.
     



    Tighten the delivery pipes bolts to 84 inch lbs. (10 Nm), once the injectors are properly seated
     
    No. 2 fuel pipe with union bolts and gaskets. Tighten the bolts to 24 ft. lbs. (32 Nm).
     
    No. 1 fuel pipe with pulsation damper, using 4 new gaskets. Tighten the damper to 35 ft. lbs. (32 Nm) and the bolt to 11 ft. lbs. (15 Nm).
     
    Fuel pressure regulator, if removed
     
    Intake manifold. Tighten the 9 bolts and 2 nuts in a crisscross pattern to 11 ft. lbs. (15 Nm).
     

  2.  
  3. Retighten the water outlet mounting nuts/bolts to 11 ft. lbs. (15 Nm), if loosened.
  4.  
  5. Install or connect the following:

    Air assist hose and water inlet pipe, using a new O-ring, by applying a small amount of soapy water. Tighten the fastener(s) to 14 ft. lbs. (20 Nm).
     
    Ground strap
     
    Vacuum hoses removed to the air intake chamber and vacuum tank
     
    Any remaining components, using new gaskets. Tighten the air intake chamber nuts/bolts to 32 ft. lbs. (43 Nm), the EGR pipe nuts to 108 inch lbs. (12 Nm) and the emission control valve set to 69 inch lbs. (8 Nm).
     
    Air cleaner assembly
     
    Heater hoses
     
    Battery and tray
     
    Throttle cable with bracket onto the throttle body
     
    Accelerator cable, by adjusting it, if equipped with an automatic transaxle
     
    Front upper suspension brace. Tighten the nuts to 59 ft. lbs. (80 Nm).
     

  6.  
  7. Refill the cooling system
  8.  
  9. Install or connect the following:

    Negative battery cable
     
    Heater air duct
     
    Left and right ventilator louvers
     
    Window washer hoses from the ventilator louvers
     
    Top cowl seal and panel
     
    Wiper and blade assembly
     

  10.  
  11. Start the engine and inspect for leaks.
  12.  

Hybrid
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the coolant from the engine radiator and hybrid transaxle.
  8.  
  9. Remove the service plug grip, found underneath the Battery Service cover on the rear seat. Wait 5 minutes to discharge the high voltage capacitor.
  10.  
  11. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover
     
    Right-hand front wheel
     
    Engine splash shields
     
    Right-hand front fender apron seal
     
    Wiper and blade assembly
     
    Top cowl ventilator louver assembly
     
    Wiper motor and link assembly
     
    Battery and battery tray
     
    Air intake assembly
     
    Converter with Inverter assembly
     
    Emission control valve set
     
    Intake air surge tank
     
    Fuel supply hose
     
    Heater inlet hose
     
    Intake manifold ground cable
     
    Fuel injector connectors
     

  12.  
  13. Loosen the intake manifold mounting bolts in several steps, in sequence as shown.
  14.  
  15. Remove the intake manifold and gaskets.

    Click image to see an enlarged view

    Fig. Intake manifold removal sequence

  16.  

To install:

  1. Install the intake manifold and gaskets. Tighten the bolts in sequence to 11 ft. lbs. (15 Nm).

    Click image to see an enlarged view

    Fig. Intake manifold installation sequence

  2.  
  3. Install or connect the following:

    Fuel injector connectors
     
    Intake manifold ground cable. Tighten to 11 ft. lbs. (15 Nm).
     
    Heater inlet hose. Tighten to 74 inch lbs. (8.4 Nm).
     
    Fuel supply hose
     
    Intake air surge tank
     
    Emission control valve set
     
    Converter with Inverter assembly
     
    Air intake assembly
     
    Battery and battery tray
     
    Wiper motor and link assembly
     
    Top cowl ventilator louver assembly
     
    Wiper and blade assembly
     
    Right-hand front fender apron seal
     
    Engine splash shields
     
    Right-hand front wheel
     
    Engine cover
     
    Negative battery cable
     

  4.  
  5. Refill the engine oil to the correct level.
  6.  
  7. Refill the coolant to the engine radiator and hybrid transaxle to the correct level.
  8.  
  9. Replace the service plug grip.
  10.  
  11. If necessary, perform the initialization procedure, as outlined in the Chassis Electrical System.
  12.  
  13. Start the engine and check for leaks.
  14.  

 
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