Genuine 2004 Toyota Sienna Intake Manifold

2004 Toyota Sienna Intake Manifold Parts Questions & Experts Answers

• Q: How to remove and install Intake Manifold in 3.0L and 3.3L V6 engine for the 2004 Toyota Sienna?

  A: Wait until the engine is completely cool before beginning this procedure. To remove the upper intake plenum, relieve the fuel system pressure and disconnect the negative cable from the battery. Drain the coolant into a clean container, then remove the V-bank cover by using an Allen wrench to take out the two bolts and pulling it up, noting that models from 1998 to 2000 have clips under the "finned" area while later models have three nuts and one large wingnut. Next, remove the air cleaner assembly and disconnect the electrical connectors, vacuum, and coolant bypass hoses from the throttle body, followed by disconnecting the throttle linkage; the throttle body can remain attached unless cleaning or gasket service is needed. For models with EGR, disconnect the EGR pipe at the intake plenum, unbolt the brace to the throttle body and engine lifting, then remove the bolts and nuts holding the plenum to the lower intake manifold and lift it off. For the lower intake manifold, disconnect the electrical connectors from the fuel injectors, noting that the manifold can be removed with the injectors and fuel rails in place or removed depending on the work required. Detach the air assist and heater hoses at the left end of the intake manifold and detach the fuel line from the fuel rail, using only your hand for the quick-connect fittings. Remove the eight mounting nuts/bolts to detach the manifold from the engine, taking care not to pry between the gasket mating surfaces to avoid damage. A water transfer hose should be replaced whenever the intake manifold is off for other repairs, as it is difficult to access. For installation, use a scraper to remove all traces of old gasket material and sealant from the manifold and cylinder heads, then clean the mating surfaces with lacquer thinner or acetone. Install new gaskets, position the manifold on the engine ensuring the gaskets haven't shifted, and install the nuts/bolts, tightening them in three or four equal steps according to the specified sequence. Install the remaining parts in reverse order of removal, using a new gasket between the intake manifold and the plenum, then refill the cooling system and run the engine to check for fuel, vacuum, and coolant leaks.