Toyota Pick-ups/Land Cruiser/4Runner 1989-1996

Intake Manifold

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REMOVAL & INSTALLATION



22R Engines
  1. Disconnect the negative battery cable first.
  2.  
  3. Drain the cooling system.
  4.  


CAUTION
When draining coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. Coolant may be reused unless it is contaminated or several years old.

  1. Remove the air cleaner assembly, complete with hoses, from the carburetor.
  2.  
  3. Label and disconnect the vacuum lines from the EGR valve and carburetor. Disconnect the EGR pipe from the manifold; remove the EGR valve with the pipe attached.
  4.  
  5. Remove the fuel lines, electrical leads, accelerator linkage, and water hose from the carburetor.
  6.  
  7. Remove the water bypass hose from the manifold.
  8.  
  9. Unbolt and remove the intake manifold, complete with carburetor and EGR valve.
  10.  
  11. Cover the cylinder head ports with clean shop cloths to keep anything from falling into the cylinder head or block.
  12.  

To install:
  1. When installing the manifold, always replace the gasket with a new one. Tighten the mounting nuts and bolts to 14 ft. lbs. (19 Nm). Tighten the bolts in several stages working from the inside bolts outward.
  2.  
  3. Connect the bypass line and all other lines and hoses.
  4.  
  5. Install the air cleaner and refill the cooling system.
  6.  
  7. Start the engine and check for leaks. Top off any fluid levels.
  8.  

22R-E Engines

See Figures 1 and 2

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  

  1. Disconnect the air intake hose from both the air cleaner assembly on one end and the air intake chamber on the other.
  2.  
  3. Tag and disconnect all vacuum lines attached to the intake chamber and manifold.
  4.  
  5. Tag and disconnect the wires to the cold start injector, throttle position sensor, and the water hoses from the throttle body.
  6.  
  7. Remove the EGR valve from the intake chamber.
  8.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the intake manifold and air intake chamber on the 22R-E engine

  1. Tag and disconnect the actuator cable, accelerator cable and automatic transmission throttle cable (if equipped) from the cable bracket on the intake chamber.
  2.  
  3. Unbolt the air intake chamber from the intake manifold and remove the chamber with the throttle body attached.
  4.  
  5. Disconnect the fuel hose from the fuel delivery pipe.
  6.  
  7. Disconnect the air valve hose from the intake manifold.
  8.  
  9. Make sure all hoses, lines and wires are tagged for later installation and disconnected from the intake manifold. Unbolt the air intake chamber from the intake manifold.
  10.  
  11. Unbolt the manifold from the cylinder head, removing the delivery pipe and injection nozzles with the manifold.
  12.  



Click image to see an enlarged view

Fig. Fig. 2: With the air intake chamber removed, the manifold can now be accessed for removal

To install:
  1. Position a new gasket on the cylinder head.
  2.  
  3. Install the intake manifold with the fuel delivery pipe and injection nozzles.
  4.  
  5. Install the bolts and nuts. Tighten them evenly to 14 ft. lbs. (19 Nm).
  6.  
  7. Install the EGR valve. Clean the bolt threads, removing any carbon or oil deposits. For the bolt closest to the front of the engine, apply sealant to the 2 or 3 threads closest to the end of the bolt. Install the bolts and nuts.
  8.  
  9. Install the air intake chamber with the throttle body. Use a new gasket. Tighten the bolts to 14 ft. lbs. (19 Nm).
  10.  
  11. Install the EGR wires and hoses.
  12.  
  13. Connect the air valve hose.
  14.  
  15. Connect the fuel hose to the fuel delivery pipe.
  16.  
  17. Install the actuator cable, accelerator cable, and throttle control cable (auto. trans.).
  18.  
  19. Connect the wires to the cold start injector, fuel injectors, throttle position sensor. Connect the water hoses to the throttle body.
  20.  
  21. Connect the vacuum lines.
  22.  
  23. Install the air intake tubing.
  24.  
  25. Refill the cooling system with coolant.
  26.  
  27. Connect the negative battery cable.
  28.  
  29. Start the engine and check for leaks. Top off any fluid levels.
  30.  

3VZ-E Engines

See Figures 3 and 4

  1. Disconnect the negative battery cable.
  2.  


WARNING
The air bag system is equipped with a back-up power source. To avoid possible air bag deployment, do not start working on the vehicle until 90 seconds has elapsed from the time the ignition switch is turned OFF and the negative battery terminal is disconnected.

  1. Drain the cooling system.
  2.  

  1. Disconnect the air intake hose from both the air cleaner assembly on one end and the air intake chamber on the other.
  2.  
  3. Tag and disconnect all vacuum lines attached to the intake chamber and manifold.
  4.  
  5. Disconnect the throttle position sensor connector at the air chamber. Disconnect the PCV hose at the union.
  6.  
  7. Disconnect the water bypass hose at the manifold. Remove the bypass hose at the water bypass pipe.
  8.  
  9. Disconnect the cold start injector and the vacuum hose at the fuel filter.
  10.  
  11. Remove the union bolt and two gaskets and then remove the cold start injector tube.
  12.  
  13. Disconnect the EGR gas temperature sensor (Calif.) and the EGR vacuum hoses from the air pipe and the vacuum modulator.
  14.  
  15. Remove the EGR valve.
  16.  
  17. Disconnect the air hose at the reed valve.
  18.  
  19. Remove the air intake chamber and then remove the engine wire harness (held with 2 bolts).
  20.  



Click image to see an enlarged view

Fig. Fig. 3: There are 7 bolts securing the air intake chamber on the 3VZ-E engine

  1. Remove the four union bolts and then remove fuel pipes.
  2.  
  3. Remove the timing belt covers.
  4.  
  5. Remove the fuel delivery pipes with their injectors.
  6.  
  7. Remove the water bypass outlet. Progressively loosen the retaining bolts and remove the intake manifold.
  8.  



Click image to see an enlarged view

Fig. Fig. 4: The intake manifold bolts can be accessed after the intake chamber is removed

To install:
  1. Install the intake manifold with new gaskets and tighten the mounting bolts to 29 ft. lbs. (39 Nm).
  2.  
  3. Install the water bypass outlet and tighten the two bolts to 13 ft. lbs. (18 Nm).
  4.  
  5. Install the fuel delivery pipes and injectors.
  6.  
  7. Install the timing belt covers and tighten the bolts to 74 inch lbs. (8.3 Nm).
  8.  
  9. Install the fuel pipes and tighten the union bolts to 22 ft. lbs. (29 Nm).
  10.  
  11. Install the engine wire harness.
  12.  
  13. Install the air intake chamber and tighten the nuts and bolts to 13 ft. lbs. (18 Nm).
  14.  
  15. Install the EGR valve and connect all hoses and lines.
  16.  
  17. Install the air cleaner duct.
  18.  
  19. Refill the engine with coolant.
  20.  
  21. Connect the negative battery cable.
  22.  
  23. Start the engine and check for leaks. Top off any fluid levels.
  24.  

3F-E Engine

See Figures 5 and 6

  1. Drain the engine coolant.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Disconnect the accelerator and throttle control cable.
  6.  
  7. Remove the air intake hose, air flow meter and air cleaner.
  8.  
  9. Disconnect or reposition all the wires and hoses running near or through the intake and exhaust manifolds. Remove the heat shields from the exhaust manifold.
  10.  
  11. Disconnect the exhaust pipes from the exhaust manifold.
  12.  
  13. Progressively loosen the retaining bolts holding the intake and exhaust manifold
  14.  
  15. Remove the intake and exhaust manifolds. They are individual pieces. Remove the combination gasket.
  16.  

To install:
  1. Place a new gasket so that the FRONT mark is towards the front side, facing outward.
  2.  



Click image to see an enlarged view

Fig. Fig. 5: Position the gasket on the engine as shown

  1. Install the intake and exhaust manifolds with the ten bolts, four plate washers and nuts. Tighten the nuts and bolts correctly. Use the illustration for correct placement:
  2.  



(A) 17mm bolts-51 ft. lbs. (69 Nm)
 
(B) 14 mm bolts-37 ft. lbs. (50 Nm)
 
(C) nuts-41 ft. lbs. (56 Nm)
 



Click image to see an enlarged view

Fig. Fig. 6: Be sure to install the fasteners in the correct locations

  1. Install new gaskets and secure the exhaust pipes to the manifold.
  2.  
  3. Install the heat shields and manifold support.
  4.  
  5. Connect the wires and hoses removed in Step 5.
  6.  
  7. Install the air cleaner, air flow meter and air intake duct.
  8.  
  9. Connect the accelerator and throttle control cables.
  10.  
  11. Fill the system with coolant.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Start the engine and check for leaks. Top off any fluids.
  16.  

5VZ-FE Engine

See Figures 7 and 8

  1. Relieve the fuel pressure.
  2.  



Click image to see an enlarged view

Fig. Fig. 7: Exploded view of the air intake chamber assembly



Click image to see an enlarged view

Fig. Fig. 8: Exploded view of the intake manifold assembly


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. Disconnect the negative battery cable.
  2.  


WARNING
The air bag system is equipped with a back-up power source. To avoid possible air bag deployment, do not start working on the vehicle until 90 seconds has elapsed from the time the ignition switch is turned OFF and the negative battery terminal is disconnected.

  1. Drain the engine coolant.
  2.  
  3. Remove the air cleaner hose.
  4.  
  5. Disconnect the following cables:
  6.  



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

  1. If equipped with an EGR valve, remove the EGR pipe and gaskets.
  2.  
  3. Remove the intake chamber stay as follows:
    1. Remove the oil filler tube and the throttle cable clamp.
    2.  
    3. Remove the intake chamber stay.
    4.  

  4.  
  5. Remove the following connectors:

    Vacuum Switching Valve (VSV) connector for the fuel pressure control
     
    Throttle positioning sensor
     
    Idle Air Control (IAC) valve
     
    Disconnect the EGR gas temperature connector
     
    Disconnect the VSV connector for the EGR valve
     

  6.  
  7. Disconnect the following hoses:

    PCV
     
    Water bypass
     
    Air assist from the intake air connector
     
    Two vacuum sensing hoses from the VSV
     
    EVAP
     
    Air hose from the power steering
     
    On A/C vehicles, disconnect the air hose from the idle up valve
     

  8.  
  9. Remove the bolts, nuts then the intake chamber assembly.
  10.  
  11. Remove the air intake connector as follows:
    1. Disconnect the engine wire from the intake connector.
    2.  
    3. Disconnect the two fuel return hoses.
    4.  
    5. Disconnect the brake booster vacuum hose from the intake air connector.
    6.  
    7. Remove the bolt and disconnect the ground strap from the intake air connector.
    8.  
    9. Disconnect the Data Link Connector No. 1 (DLC1) from the bracket of the intake connector.
    10.  
    11. On A/C vehicles, disconnect the idle up valve.
    12.  
    13. Remove the air intake connector from the engine.
    14.  

  12.  
  13. Disconnect the spark plug wires.
  14.  
  15. Remove the engine splash shield from under the engine.
  16.  
  17. Disconnect the upper radiator hose.
  18.  
  19. Remove the power steering, A/C and alternator belts.
  20.  
  21. Remove the fan shroud.
  22.  
  23. Remove the fan shroud with the coupling and pulleys.
  24.  
  25. Disconnect the power steering pump from the engine, then set aside. Do not disconnect the lines from the pump.
  26.  
  27. On A/C vehicles, remove the compressor. Do not disconnect the lines from the compressor, then set aside. Unbolt the bracket from the compressor.
  28.  
  29. Remove the power steering adjusting strut. Then remove the fan bracket.
  30.  
  31. Set the No. 1 cylinder at TDC of the compression stroke as follows:
    1. Turn the crankshaft pulley and align it's groove with the timing mark 0 of the timing belt cover.
    2.  
    3. Check the timing marks of the camshaft timing pulleys and the timing belt cover are aligned. If not, turn the crankshaft pulley one revolution (360°).
    4.  

  32.  

If reusing the timing belt, make sure that you can still read the installation marks. If not, place new marks on the belt to match the timing marks of the camshaft timing pulleys.

  1. Remove the timing belt tensioner by alternately loosening the bolts.
  2.  
  3. Remove the camshaft timing pulleys.
  4.  
  5. Remove the crankshaft pulley.
  6.  
  7. Remove the timing belt idler pulley.
  8.  
  9. Disconnect and remove the fuel pressure regulator.
  10.  
  11. Disconnect the heater hose.
  12.  
  13. Disconnect the engine wiring from the intake manifold:

    Oil pressure sensor
     
    Crankshaft position sensor
     
    Injectors
     
    ECT sender gauge
     
    ECT sensor
     
    Knock sensor
     
    Camshaft position sensor
     
    Disconnect the engine wire clamps
     
    Remove the bolts, then disconnect the engine wire from the cylinder head
     

  14.  
  15. Remove the camshaft position sensor.
  16.  
  17. Unbolt the No. 3 (rear) timing belt cover.
  18.  
  19. Disconnect the fuel inlet hose, then remove the bo,to securing the intake manifold stay.
  20.  
  21. Unbolt the intake manifold assembly.
  22.  

To install:
  1. Clean all mating surfaces.
  2.  
  3. Install new gaskets on the intake and tighten down to 13 ft. lbs. (18 Nm).
  4.  
  5. Install the intake stay, tighten to 14 ft. lbs. (18 Nm).
  6.  
  7. Connect the fuel inlet hose.
  8.  
  9. Attach the timing cover, tighten the bolts to 80 inch lbs. (9 Nm).
  10.  
  11. Install the camshaft position sensor, tighten to 71 inch lbs. (8 Nm).
  12.  
  13. Attach all the engine wiring to the intake manifold.
  14.  
  15. Install the heater hose.
  16.  
  17. Attach the fuel pressure regulator.
  18.  
  19. Install the timing belt idler.
  20.  
  21. Attach the left camshaft timing pulley as follows:
    1. Install the knock pin to the camshaft.
    2.  
    3. Align the knock pin hose of the camshaft with the knock pin groove of the timing pulley.
    4.  
    5. Slide the timing pulley on the camshaft with the flange side facing outward. Tighten the pulley bolt to 81 ft. lbs. (110 Nm).
    6.  

  22.  
  23. Set the No. 1 cylinder to TDC of the compression stroke.
  24.  
  25. Connect the timing belt to the left camshaft timing pulley. Check that the installation mark of the timing belt is aligned with the end of the timing belt cover.
    1. Using a SST 09960-01000 or equivalent, slightly turn the left camshaft timing pulley clockwise. Align the installation mark with the timing belt on the camshaft pulley. Hang the timing belt on the left camshaft pulley.
    2.  
    3. Align the timing marks of the left camshaft pulley and the timing belt cover.
    4.  
    5. Check that the timing belt has tension between the crankshaft timing pulley and the left camshaft pulley.
    6.  

  26.  
  27. Install the right camshaft pulley and belt:
    1. Align the installation mark with the timing belt on the camshaft pulley. Hang the timing belt on the right camshaft pulley with the flange facing inward.
    2.  
    3. Slide the right camshaft pulley on the camshaft. Align the timing marks on the right pulley and the timing belt cover.
    4.  
    5. Align the knock pin hole of the camshaft with the knock pin groove of the pulley, then install the knock pin. Install the bolt and tighten to 81 ft. lbs. (110 Nm).
    6.  

  28.  
  29. Set the timing belt tensioner:
    1. Using a press, slowly press in the pushrod using 220-2205 lbs. (981-9807 N) of force.
    2.  
    3. Align the holes of the pushrod and housing, pass a 1.5mm hexagon wrench through the holes to keep the setting position of the pushrod.
    4.  
    5. Release the press and install the dust boot to the tensioner.
    6.  

  30.  
  31. Install the timing belt tensioner and alternately tighten the bolts to 20 ft. lbs. (28 Nm). Using pliers, remove the 1.5 mm hexagon wrench from the belt tensioner.
  32.  
  33. Check the valve timing.
  34.  
  35. Install the fan bracket.
  36.  
  37. Install the power steering adjusting strut.
  38.  
  39. Install the timing belt cover. Tighten the bolts to 80 inch lbs. (9 Nm).
  40.  
  41. Connect the clamps for the spark plug wires to the timing belt cover.
  42.  
  43. Connect the camshaft position sensor to the timing belt cover.
  44.  
  45. On vehicles with A/C, install the compressor bracket and compressor.
  46.  
  47. Attach the fan with coupling and pulleys, tighten the nuts to 48 inch lbs. (5 Nm).
  48.  
  49. Install the fan shroud.
  50.  
  51. Install the alternator belt and cooling fan, tighten the fan nuts to 4 ft. lbs. (5 Nm).
  52.  
  53. Install the A/C belt.
  54.  
  55. Attach the power steering pump, pulley and drive belt.
  56.  
  57. Connect the upper radiator hose.
  58.  
  59. Fill the radiator with a coolant/water mixture.
  60.  
  61. Connect the spark plug wires to the plugs.
  62.  
  63. Install the intake air connector:
    1. Install the intake manifold, then tighten the bolts and nuts to 14 ft. lbs. (18 Nm).
    2.  
    3. Connect the DLC1 to the bracket on the intake manifold.
    4.  
    5. Connect the ground strap to the manifold.
    6.  
    7. Attach the brake booster vacuum hose to the intake air connector.
    8.  
    9. Connect the two fuel return hoses.
    10.  
    11. Attach the engine wire to the intake manifold.
    12.  
    13. On A/C models, connect the idle up valve connector.
    14.  

  64.  
  65. Install the air intake chamber assembly, tighten the bolts to 14 ft. lbs. (18 Nm).
  66.  
  67. Attach these hoses:

    PCV
     
    Water bypass
     
    Air assist from the intake air connector
     
    Two vacuum sensing hoses from the VSV
     
    EVAP
     
    Air hose from the power steering
     
    On A/C vehicles, connect the air hose to the idle up valve
     

  68.  
  69. Connect the following wiring:

    Vacuum Switching Valve (VSV) connector for the fuel pressure control
     
    Throttle positioning sensor
     
    Idle Air Control (IAC) Valve
     
    Connect the EGR gas temperature connector
     
    Connect the VSV connector for the EGR valve
     

  70.  
  71. Install the intake chamber stay:
    1. Install the intake chamber stay bolts, tighten to 30 ft. lbs. (40 Nm).
    2.  
    3. Install a new O-ring to the oil filler tube.
    4.  
    5. Push the oil filler tube end into the tube hole in the pan.
    6.  
    7. Attach the filler tube and the throttle cable clamp.
    8.  

  72.  
  73. Install new gaskets on the EGR pipe. Tighten the clamp nuts to 71 inch lbs. (8 Nm), and the EGR pipe nuts to 14 ft. lbs. (18 Nm).
  74.  
  75. Connect the cables removed earlier.
  76.  
  77. Install the air cleaner hose.
  78.  
  79. Fill the radiator with a mixture of coolant and water.
  80.  
  81. Start the engine and check for leaks. Top off any fluids.
  82.  

1FZ-FE Engine

See Figure 9

  1. Relieve the fuel pressure.
  2.  

  1. Disconnect the negative battery cable.
  2.  


WARNING
The air bag system is equipped with a back-up power source. To avoid possible air bag deployment, do not start working on the vehicle until 90 seconds has elapsed from the time the ignition switch is turned OFF and the negative battery terminal is disconnected.

  1. Drain the engine coolant.
  2.  
  3. Remove the air cleaner hose and cap.
  4.  
  5. Disconnect the following cables:

    On cruise control vehicles, the actuator cable from the throttle body
     
    Accelerator cable
     
    Throttle cable (auto transmission)
     

  6.  
  7. Disconnect the engine ground strap from the engine hanger and the ground strap from the air intake chamber.
  8.  
  9. Detach the connection on the intake manifold from the left fender apron.
  10.  
  11. Disconnect the brake booster and EVAP hoses.
  12.  
  13. Separate the fuel inlet and return lines from the fuel rail.
  14.  
  15. Remove the intake manifold stay.
  16.  



Click image to see an enlarged view

Fig. Fig. 9: Remove the two bolts securing the intake manifold stay

  1. Disconnect the following electrical connections:

    Engine Coolant Temperature (ECT) sender gauge
     
    ECT cut switch
     
    ECT sensor
     
    Knock sensor
     
    Crankshaft position sensor
     

  2.  
  3. Remove the bolt that secures the engine harness to the cylinder block.
  4.  
  5. Disconnect the PCV hose from the PCV valve.
  6.  
  7. Remove the bolt that secures the engine harness to the intake manifold.
  8.  
  9. Disconnect the following:

    Engine wire clamps
     
    EGR temperature sensor connector
     
    The fuel injector connections
     
    The connector for the emission control valve set
     

  10.  
  11. Remove the water bypass pipe.
  12.  
  13. Remove the air intake chamber and the intake manifold assembly.
    1. Disconnect the vacuum hoses at the Thermal Vacuum (TVV) Valve.
    2.  
    3. Remove the bolts securing the intake manifold and gasket.
    4.  

  14.  

To install:
  1. Install the air intake chamber and intake manifold assembly:
    1. Place a new gasket so that the rear mark is toward the rear side.
    2.  
    3. Tighten the intake manifold bolts to 15 ft. lbs. (21 Nm).
    4.  
    5. Connect the vacuum hoses to the TVV.
    6.  

  2.  
  3. Install the water bypass pipe.
  4.  
  5. Connect the following:

    Engine wire clamps
     
    EGR gas temperature sensor connection
     
    Fuel injector connections
     
    The connector for the emission control valve set
     

  6.  
  7. Install the bolt that secures the engine wire harness to the intake manifold.
  8.  
  9. Connect the PCV hose to the PCV valve.
  10.  
  11. Install the bolt that secures the engine wire harness to the cylinder block.
  12.  
  13. Connect the following wires:

    Engine Coolant Temperature (ECT) sender gauge
     
    ECT cut switch
     
    ECT sensor
     
    Knock sensor
     
    Crankshaft position sensor
     

  14.  
  15. Attach the intake manifold stay and tighten the bolts to 26 ft. lbs. (36 Nm).
  16.  
  17. Install the radiator inlet hose, the water bypass hose, and the alternator.
  18.  
  19. Install the heater hose to the cylinder head, then connect the pipe to the intake manifold. Tighten the bolts to 15 ft. lbs. (21 Nm).
  20.  
  21. Connect the fuel inlet and return hoses to the fuel rail.
  22.  
  23. Connect the brake booster and EVAP hoses.
  24.  
  25. Attach the connector on the intake manifold to the left fender apron.
  26.  
  27. Connect the ground straps to the engine hanger and the air intake chamber.
  28.  
  29. Attach the throttle cable to the throttle body.
  30.  
  31. Attach the accelerator cable to the throttle body.
  32.  
  33. Install the air cleaner hose and cap.
  34.  
  35. Connect the negative battery cable.
  36.  
  37. Refill the coolant and water mixture to the radiator.
  38.  
  39. Start the engine and check for leaks. Top off any fluids.
  40.  

 
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