Toyota Sienna 2000-06

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. 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
     

  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, on automatic transaxles
     
    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 martial off.
  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
     

  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.  

3.0L And 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
     

  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:

    Accelerator cable, on automatic transaxles
     
    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.
     

  12.  


NOTE
The delivery pipes with injectors will be attached to the manifold.



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

  1. Clean and inspect the intake manifold mating surfaces. Scrape all old gasket martial off.
  2.  

To install:

  1. Install or connect the following:

    Delivery pipes with injectors to the intake manifold.
     

  2.  


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.



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).
 


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

  1. Retighten the water outlet mounting nuts/bolts to 11 ft. lbs. (15 Nm), if loosened.
  2.  
  3. 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
     

  4.  
  5. Refill the cooling system
  6.  
  7. 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
     

  8.  
  9. Start the engine and inspect for leaks.
  10.  

3.0L Engine
  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
     

  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, on automatic transaxles
     
    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 martial off.
  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
     

  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.  

3.3L Engines
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Drain the engine oil.
  8.  
  9. Drain and recycle the engine coolant.
  10.  
  11. Remove the right hand front wheel.
  12.  
  13. Remove the wiper arms.
  14.  
  15. Remove the cowl panel.
  16.  
  17. Remove the wiper link assembly.
  18.  
  19. Remove the cowl top to inner brace.
  20.  
  21. Remove the cowl top cover outer sub assembly.
  22.  
  23. Remove the engine cover.
  24.  
  25. Remove the air cleaner assembly.
  26.  
  27. Remove the emission control valve set.
  28.  
  29. Remove the air surge tank.
  30.  
  31. Disconnect the fuel pipe sub assembly.
  32.  
  33. Disconnect the heater hose inlet pipe.
  34.  
  35. Remove the nut and ground cable.
  36.  
  37. Disconnect the fuel injector connectors.
  38.  
  39. Remove the intake manifold nuts and bolts in the sequence shown using several passes.
  40.  
  41. Remove the intake manifold.

    Click image to see an enlarged view

    Fig. Remove the intake manifold nuts and bolts in the sequence shown-3.3L engine

  42.  

To install:

  1. Install the intake manifold. Tighten the retainers using several passes to 11 ft. lbs. (15 Nm).
  2.  
  3. Install the remaining components in the reverse order of removal.

    Click image to see an enlarged view

    Fig. Tighten the intake manifold nuts and bolts in the sequence shown-3.3L engine

  4.  

 
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