Toyota RAV4 2000-05

Intake Manifold

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Removal & Installation



  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
     
    Air cleaner assembly
     
    Throttle body from the intake manifold
     

  6.  
  7. Disconnect the engine wire from the intake manifold, as follows:

    4 injector connectors
     
    2 engine wire clamps from the intake manifold wire brackets
     
    Engine wire protector from the right-hand side of the intake manifold by removing the bolt
     
    Engine wire from the wire clamp
     

  8.  
  9. Remove the EGR valve, EGR pipe and modulator, as follows:

    Both vacuum hoses from the Exhaust Gas Recirculation (EGR) Vacuum Switching Valve (VSV)
     
    Vacuum modulator from the clamp on the intake manifold
     
    Loosen the cylinder head side of the EGR pipe union nut
     
    Both nuts, the EGR valve, pipe assembly and gasket
     
    Vacuum modulator
     

  10.  
  11. Disconnect the following hoses:

    Fuel filter vacuum sensor hose on the intake manifold
     
    Brake booster vacuum hose from the intake manifold
     
    Ground strap from the intake manifold
     

  12.  
  13. Remove or disconnect the following:

    Intake manifold stay by removing the 2 bolts
     
    Control cable from the clamp on the rear side of the intake manifold, if equipped with automatic transmission
     
    Air hose from the intake manifold
     
    Air tube from the intake manifold, by removing the 2 bolts
     
    6 bolts and 2 nuts from the intake manifold
     
    Intake manifold
     

  14.  

To install:

  1. Install or connect the following:

    Intake manifold. Tighten the 6 bolts and 2 nuts to 14 ft. lbs. (19 Nm).
     
    Air tube with the 2 bolts
     
    Air hose to the intake manifold
     
    Control cable to the clamp on the rear side of the intake manifold, if equipped with an automatic transmission
     
    Intake manifold stay. Tighten both bolts to 31 ft. lbs. (42 Nm).
     

  2.  
  3. Connect the following hoses:

    Ground strap to the intake manifold
     
    Brake booster vacuum hose to the intake manifold
     
    Fuel filter vacuum sensor hose to the intake manifold
     

  4.  
  5. Install the EGR valve, EGR pipe and the vacuum modulator, as follows:

    Vacuum modulator
     
    EGR valve and pipe. Tighten both nuts to 108 inch lbs. (13 Nm) and the union nut to 43 ft. lbs. (59 Nm).
     
    Vacuum hoses
     

  6.  
  7. Install or connect the following:
    NOTE
    The No. 1 and No. 3 injector connectors are brown, and the No. 2 and No. 4 injector connectors are gray.



    Engine wire and injectors
     



    Throttle body to the intake manifold
     
    Air cleaner assembly
     
    Negative battery cable
     

  8.  

2.0L 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
     
    Air cleaner assembly
     
    Throttle body from the intake manifold
     

  6.  
  7. Disconnect the engine wire from the intake manifold, as follows:

    4 injector connectors
     
    2 engine wire clamps from the intake manifold wire brackets
     
    Engine wire protector from the right-hand side of the intake manifold by removing the bolt
     
    Engine wire from the wire clamp
     

  8.  
  9. Remove the EGR valve, EGR pipe and modulator, as follows:

    Both vacuum hoses from the Exhaust Gas Recirculation (EGR) Vacuum Switching Valve (VSV)
     
    Vacuum modulator from the clamp on the intake manifold
     
    Loosen the cylinder head side of the EGR pipe union nut
     
    Both nuts, the EGR valve, pipe assembly and gasket
     
    Vacuum modulator
     

  10.  
  11. Disconnect the following hoses:

    Fuel filter vacuum sensor hose on the intake manifold
     
    Brake booster vacuum hose from the intake manifold
     
    Ground strap from the intake manifold
     

  12.  
  13. Remove or disconnect the following:

    Intake manifold stay by removing the 2 bolts
     
    Control cable from the clamp on the rear side of the intake manifold, if equipped with automatic transmission
     
    Air hose from the intake manifold
     
    Air tube from the intake manifold, by removing the 2 bolts
     
    6 bolts and 2 nuts from the intake manifold
     
    Intake manifold
     

  14.  

To install:

  1. Install or connect the following:

    Intake manifold. Tighten the 6 bolts and 2 nuts to 14 ft. lbs. (19 Nm).
     
    Air tube with the 2 bolts
     
    Air hose to the intake manifold
     
    Control cable to the clamp on the rear side of the intake manifold, if equipped with an automatic transmission
     
    Intake manifold stay. Tighten both bolts to 31 ft. lbs. (42 Nm).
     

  2.  
  3. Connect the following hoses:

    Ground strap to the intake manifold
     
    Brake booster vacuum hose to the intake manifold
     
    Fuel filter vacuum sensor hose to the intake manifold
     

  4.  
  5. Install the EGR valve, EGR pipe and the vacuum modulator, as follows:

    Vacuum modulator
     
    EGR valve and pipe. Tighten both nuts to 108 inch lbs. (13 Nm) and the union nut to 43 ft. lbs. (59 Nm).
     
    Vacuum hoses
     

  6.  
  7. Install or connect the following:

    Engine wire and injectors
     

  8.  


NOTE
The No. 1 and No. 3 injector connectors are brown, and the No. 2 and No. 4 injector connectors are gray.



Throttle body to the intake manifold
 
Air cleaner assembly
 
Negative battery cable
 

  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
     
    Air cleaner assembly
     
    Throttle body from the intake manifold
     

  6.  
  7. Disconnect the engine wire from the intake manifold, as follows:

    4 injector connectors
     
    2 engine wire clamps from the intake manifold wire brackets
     
    Engine wire protector from the right side of the intake manifold by removing the bolt
     
    Engine wire from the wire clamp
     

  8.  
  9. Remove the EGR valve, EGR pipe and modulator, as follows:

    Both vacuum hoses from the Exhaust Gas Recirculation (EGR) Vacuum Switching Valve (VSV)
     
    Vacuum modulator from the clamp on the intake manifold
     
    Loosen the cylinder head side of the EGR pipe union nut
     
    Both nuts, the EGR valve, pipe assembly and gasket
     
    Vacuum modulator
     

  10.  
  11. Disconnect the following hoses:

    Fuel filter vacuum sensor hose on the intake manifold
     
    Brake booster vacuum hose from the intake manifold
     
    Ground strap from the intake manifold
     

  12.  
  13. Remove or disconnect the following:

    Intake manifold stay by removing the 2 bolts
     
    Control cable from the clamp on the rear side of the intake manifold, if equipped with automatic transaxle
     
    Air hose from the intake manifold
     
    Air tube from the intake manifold, by removing the 2 bolts
     
    6 bolts and 2 nuts from the intake manifold
     
    Intake manifold
     

  14.  

To install:

  1. Install or connect the following:

    Intake manifold. Tighten the 6 bolts and 2 nuts to 14 ft. lbs. (19 Nm).
     
    Air tube with the 2 bolts
     
    Air hose to the intake manifold
     
    Control cable to the clamp on the rear side of the intake manifold, if equipped with an automatic transaxle
     
    Intake manifold stay. Tighten both bolts to 31 ft. lbs. (42 Nm).
     

  2.  
  3. Connect the following hoses:

    Ground strap to the intake manifold
     
    Brake booster vacuum hose to the intake manifold
     
    Fuel filter vacuum sensor hose to the intake manifold
     

  4.  
  5. Install the EGR valve, EGR pipe and the vacuum modulator, as follows:

    Vacuum modulator
     
    EGR valve and pipe. Tighten both nuts to 108 inch lbs. (13 Nm) and the union nut to 43 ft. lbs. (59 Nm).
     
    Vacuum hoses
     

  6.  
  7. Install or connect the following:
    NOTE
    The No. 1 and No. 3 injector connectors are brown, and the No. 2 and No. 4 injector connectors are gray.



    Engine wire and injectors
     



    Throttle body to the intake manifold
     
    Air cleaner assembly
     
    Negative battery cable
     

  8.  

 
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