Toyota Tundra 2001-06

Intake Manifold

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Removal & Installation



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 undercover.
  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.  

  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 undercover.
  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 4WD
     
    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

    Click image to see an enlarged view

    Fig. Intake manifold bolts and nuts-3.4L engine

     

  16.  

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 4WD
     
    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.  

4.0L Engine


Click image to see an enlarged view

Fig. Intake manifold and related components-4.0L engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Properly disarm the SRS system.
  6.  
  7. Disconnect the negative battery cable.
  8.  
  9. Drain the engine coolant. Remove the air cleaner assembly.
  10.  
  11. Disconnect the fuel injector wiring connectors.
  12.  
  13. Remove the necessary components in order to gain access to the intake manifold retaining bolts.
  14.  
  15. Remove the intake manifold retaining bolts. Remove the intake manifold from the engine.
  16.  

To install:

  1. Clean all surfaces.
  2.  
  3. Install a new gasket on each cylinder head.
    NOTE
    Align the ports of the gasket and the cylinder head. Be careful of the installation direction. Position the intake manifold to the engine.

  4.  
  5. Install the retaining bolts and tighten to specification, in an alternating sequence.
  6.  
  7. Continue the installation in the reverse order of the removal procedure.
  8.  
  9. Be sure to fill the cooling system with the proper grade and type engine coolant.
  10.  
  11. Start the engine and check for leaks. Correct as required.
  12.  

4.7L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Engine appearance cover
     
    Accelerator cable
     
    Throttle Position (TP) sensor connector
     
    Accelerator pedal position sensor
     
    Throttle motor connector
     
    Evaporative Emissions (EVAP) vacuum switching valve connector
     
    Fuel injector connectors
     
    Engine Coolant Temperature (ECT) sensor connector
     
    ETC gauge sender connector
     
    Heated Oxygen (HO2S) sensor connectors
     
    Fuel pressure regulator vacuum hose
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    EVAP hoses
     
    Power steering vacuum hoses
     
    Water bypass hose
     
    Engine control wiring harness clamps
     
    Cylinder head ground cables
     
    Intake manifold wire harness protector
     
    EVAP pipe
     
    Engine appearance cover brackets
     
    Intake manifold
     

  8.  

To install:

  1. Install or connect the following:

    Intake manifold. Tighten the fasteners to 13 ft. lbs. (18 Nm).
     
    Engine appearance cover brackets
     
    EVAP pipe
     
    Intake manifold wire harness protector
     
    Cylinder head ground cables
     
    Engine control wiring harness clamps
     
    Water bypass hose
     
    Power steering vacuum hoses
     
    EVAP hoses
     
    PCV valve and hose
     
    Fuel pressure regulator vacuum hose
     
    HO2S sensor connectors
     
    ETC gauge sender connector
     
    ECT sensor connector
     
    Fuel injector connectors
     
    EVAP vacuum switching valve connector
     
    Throttle motor connector
     
    Accelerator pedal position sensor
     
    TP sensor connector
     
    Accelerator cable
     
    Engine appearance cover
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  


    Click image to see an enlarged view

    Fig. Exploded of the intake manifold mounting-4.7L engine


  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Engine appearance cover
     
    Accelerator cable
     
    Throttle Position (TP) sensor connector
     
    Accelerator pedal position sensor
     
    Throttle motor connector
     
    Evaporative Emissions (EVAP) vacuum switching valve connector
     
    Fuel injector connectors
     
    Engine Coolant Temperature (ECT) sensor connector
     
    ETC gauge sender connector
     
    Heated Oxygen (HO 2 S) sensor connectors
     
    Fuel pressure regulator vacuum hose
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    EVAP hoses
     
    Power steering vacuum hoses
     
    Water bypass hose
     
    Engine control wiring harness clamps
     
    Cylinder head ground cables
     
    Intake manifold wire harness protector
     
    EVAP pipe
     
    Engine appearance cover brackets
     
    Intake manifold
     

  8.  

To install:

  1. Install or connect the following:

    Intake manifold. Tighten the fasteners to 13 ft. lbs. (18 Nm).
     
    Engine appearance cover brackets
     
    EVAP pipe
     
    Intake manifold wire harness protector
     
    Cylinder head ground cables
     
    Engine control wiring harness clamps
     
    Water bypass hose
     
    Power steering vacuum hoses
     
    EVAP hoses
     
    PCV valve and hose
     
    Fuel pressure regulator vacuum hose
     
    HO 2 S sensor connectors
     
    ETC gauge sender connector
     
    ECT sensor connector
     
    Fuel injector connectors
     
    EVAP vacuum switching valve connector
     
    Throttle motor connector
     
    Accelerator pedal position sensor
     
    TP sensor connector
     
    Accelerator cable
     
    Engine appearance cover
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.

    Click image to see an enlarged view

    Fig. Intake manifold and related components-4.7L engine

  6.  

 
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