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Home >> Toyota >> 2009 >> RAV4 Base, 3.5 K, AWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 10 (Intake (2AR-FE)) >> Intake Manifold >> Removal

Intake Manifold: Removal

WARNING: This page is about a different variant/trim than selected.
  1. DISCHARGE FUEL SYSTEM PRESSURE  (See REMOVAL )
  2. REMOVE NO. 1 ENGINE UNDER COVER  (See REMOVAL )
  3. DRAIN ENGINE COOLANT  (See COOLANT )
  4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.
  5. REMOVE FRONT WIPER MOTOR AND LINK 
    1. Remove the front wiper motor and link (See REMOVAL ).
  6. REMOVE COWL VENTILATOR HOUSING SUB-ASSEMBLY 
    1. Detach the 4 clamps and remove the cowl ventilator housing.
      Fig 1: Identifying Cowl Ventilator Housing Clamps
      G05998743Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE COWL TOP OUTER PANEL SUB-ASSEMBLY 
    1. Detach the 3 clamps and disconnect the wire harness.
    2. Remove the 14 bolts and cowl top outer panel.
      Fig 2: Identifying Wire Harness Clamps
      G05998744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 3: Locating Cowl Top Outer Panel Bolts
      G05998745Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. DISCONNECT UNION TO CONNECTOR TUBE HOSE 
    1. Disconnect the union to connector tube hose from the tube.
      Fig 4: Locating Connector Tube Hose Clamp
      G05998746Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE HOSE TO HOSE TUBE 
    1. Disconnect the hose.
    2. Remove the 2 nuts and tube.
      Fig 5: Locating Hose Tube Clamp
      G05998747Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. DISCONNECT HEATER HOSE 
    1. Disconnect the inlet heater water hose from the heater radiator unit and cylinder head.
    2. Disconnect the outlet heater water hose from the heater radiator unit and water by-pass pipe.
  11. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY  (See ON-VEHICLE INSPECTION )
  12. REMOVE AIR CLEANER CAP SUB-ASSEMBLY  (See REMOVAL )
    Fig 6: Locating Inlet Heater Water Hose Clamp
    G05998748Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE THROTTLE BODY ASSEMBLY  (See ON-VEHICLE INSPECTION )
  14. DISCONNECT FUEL TUBE SUB-ASSEMBLY  (See INSPECTION )
  15. DISCONNECT WIRE HARNESS 
    1. Disconnect the 4 injector connectors.
    2. Disconnect the 2 connectors.
    3. Remove the 2 bolts and disconnect the 2 wire harness brackets.
    4. Detach the 2 clamps.
      Fig 7: Locating Wire Harness Brackets Clamp
      G05998749Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the bolt and bracket.
      Fig 8: Locating Bracket Bolts
      G05998750Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Apply battery voltage to the terminals of the connector to close the tumble control valves.

      Standard 

      BATTERY VOLTAGE SPECIFICATION

      Tester Connection Specified Condition
      Positive battery voltage applied to terminal 8 (M-), and negative battery voltage applied to terminal 4 (M+) Open → Closed
      Fig 9: Identifying Connector Terminal
      G05998751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If this procedure is not performed, the valves may be damaged when the intake manifold is removed.
      • Apply battery voltage for 1 to 3 seconds.
      • If battery voltage is applied for more than 3 seconds, the actuator may be damaged.
      • Do not allow the lead wires to contact the other terminals.
    7. Remove the bolt.
    8. Detach the 2 clamps from the intake manifold and bracket.
    9. Disconnect the intake air control valve actuator connector.
      Fig 10: Locating Intake Air Control Valve Actuator Connector
      G05998752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Detach the clamp and wire harness.
      Fig 11: Identifying Wire Harness Clamp
      G05998753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE VACUUM SWITCHING VALVE ASSEMBLY (for ACIS) 
    1. Disconnect the 2 vacuum hoses and union to connector tube hose.
    2. Remove the bolt and vacuum switching valve assembly.
  17. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY  (See INSPECTION )
    Fig 12: Locating Vacuum Switching Valve Assembly Bolts
    G05998754Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. DISCONNECT NO. 2 VENTILATION HOSE 
    1. Disconnect the No. 2 ventilation hose from the intake manifold.
      Fig 13: Locating No. 2 Ventilation Hose Clamps
      G05998755Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE INTAKE MANIFOLD 
    1. Remove the 6 bolts and intake manifold.
      NOTE: The valves may be damaged if they are not closed before removing the intake manifold.
    2. Remove the gasket from the intake manifold.
      Fig 14: Locating Intake Manifold Bolts
      G05998756Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE UNION TO CONNECTOR TUBE HOSE 
    1. Remove the union to connector tube hose from the intake manifold.
      Fig 15: Locating Connector Tube Hose Clamp
      G05998757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE CHECK VALVE 
    1. Disconnect the 2 vacuum hoses from the intake manifold and remove the check valve.
    2. Remove the 2 vacuum hoses from the check valve.
      Fig 16: Locating Vacuum Hoses
      G05998758Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE WIRING HARNESS CLAMP BRACKET 
    1. Remove the bolt and bracket.
      Fig 17: Identifying Wiring Harness Clamp Bracket Bolts
      G05998759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE PURGE LINE HOSE 
    1. Disconnect the purge line hose from the clamp.
    2. Remove the purge line hose from the intake manifold.
    3. Detach the clamp from the intake manifold.
  24. REMOVE INTAKE AIR CONTROL VALVE ACTUATOR (for TCV)  (See REMOVAL  )
    Fig 18: Locating Purge Line Hose
    G05998760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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