This procedure covers removal and replacement of the intake manifold gasket on the 2019-2024 Toyota RAV4 2.5L I4 FWD engine, including removal of associated components and proper torque sequence during reassembly.

Warnings

Tools required

Parts

• Intake manifold gasket × 1 — Use OEM specification
• Throttle body gasket × 1 — Use OEM specification
• PCV valve grommet × 1 — Use OEM specification (if damaged)

Fluids

• Toyota Super Long Life Coolant (Pink) — 2 qt

Preparation

1. Park vehicle on level surface and allow engine to cool completely (minimum 2 hours)
2. Disconnect negative battery terminal and wait 90 seconds for airbag system discharge
3. Remove engine cover by lifting up from rear and pulling forward to release clips
4. Place drain pan under radiator and drain approximately 2 quarts of coolant from radiator drain cock
5. Relieve fuel system pressure by removing fuel pump relay and cranking engine until it stalls
6. Label or photograph all vacuum lines, electrical connectors, and hose routing for reference

Procedure

1. 1

   Remove Air Intake System
   Disconnect mass airflow sensor electrical connector. Loosen air intake hose clamp at throttle body. Remove air filter housing bolts and lift out entire air intake assembly including filter housing and intake tube. Set aside.
2. 2

   Disconnect Throttle Body and Coolant Lines
   Disconnect throttle body electrical connector. Remove coolant bypass hoses from throttle body by squeezing hose clamps and sliding off. Have shop towels ready to catch coolant spillage. If equipped with coolant crossover, remove crossover bolts and set aside.
   ⚠Coolant will drain from hoses when disconnected. Have drain pan positioned underneath.
3. 3

   Remove Throttle Body
   Remove four throttle body bolts. Carefully pull throttle body away from intake manifold. Remove and discard throttle body gasket. Plug throttle body opening with clean shop towel to prevent debris entry.
   Torque spec

   Throttle Body Bolts10 Nm (7 lb-ft)
4. 4

   Disconnect Fuel System
   Using fuel line disconnect tools, carefully disconnect fuel feed line from fuel rail. Have shop towels ready to catch residual fuel. Disconnect fuel injector electrical connectors by pressing release tabs and pulling straight up. Disconnect fuel rail pressure sensor connector.
   ⚠Fuel will leak from disconnected lines. Keep fire extinguisher nearby and ensure adequate ventilation.
5. 5

   Remove Fuel Rail Assembly
   Remove fuel rail mounting bolts. Carefully pull fuel rail with injectors straight up and out of intake manifold. Wiggle gently if needed but do not pry. Cover injector ports in intake manifold with clean shop towels to prevent debris entry. Set fuel rail assembly aside in safe location.
   Torque spec

   Fuel Rail Bolts12 Nm (9 lb-ft)
6. 6

   Disconnect PCV and Vacuum Lines
   Disconnect PCV valve from valve cover by twisting counterclockwise while pulling. Disconnect PCV hose from intake manifold. Remove all vacuum hoses from intake manifold, noting their positions. Disconnect brake booster vacuum line from intake manifold rear. Disconnect EVAP purge valve line if equipped.
7. 7

   Disconnect EGR System
   If equipped with EGR valve, disconnect EGR valve electrical connector. Remove EGR valve bolts and remove EGR valve from intake manifold. Remove and discard EGR gasket. Plug EGR opening to prevent debris entry.
8. 8

   Remove Intake Manifold Support Brackets
   Locate intake manifold support brackets on underside of manifold connecting to engine block. Remove mounting bolts securing brackets to manifold and block. Remove brackets and set aside.
9. 9

   Remove Intake Manifold
   Remove all intake manifold bolts in reverse order from center outward (opposite of tightening sequence). Carefully lift intake manifold straight up off cylinder head. If manifold is stuck, gently tap with rubber mallet. Do not pry between mating surfaces. Remove manifold and set on clean work surface with mating surface facing up.
   ⚠Manifold may be stuck due to gasket seal. Never use metal tools to pry between mating surfaces as damage will cause vacuum leaks.
   Torque spec

   Intake Manifold Bolts25 Nm (18 lb-ft)
10. 10

    Remove Old Gasket and Clean Surfaces
    Remove old intake manifold gasket from cylinder head and intake manifold mating surfaces. Use plastic razor blade scraper to carefully remove all gasket material without scratching aluminum surfaces. Clean surfaces with brake cleaner and lint-free cloth. Use shop vacuum to remove all debris from intake ports. Inspect mating surfaces for damage, warping, or scratches. Surfaces must be completely clean and dry.
    ⚠Any debris left in intake ports can be ingested into engine and cause damage. Ensure all ports are completely clean.
11. 11

    Install New Gasket and Position Manifold
    Position new intake manifold gasket on cylinder head, aligning all port openings and bolt holes. Do not use gasket sealer unless specified by manufacturer. Carefully lower intake manifold onto gasket, aligning all bolt holes. Ensure gasket remains properly positioned and does not shift.
12. 12

    Install and Torque Manifold Bolts
    Install all intake manifold bolts finger-tight. Using torque wrench, tighten bolts in sequence from center outward to 25 Nm (18 lb-ft). Follow crossing pattern, starting with center bolts and working outward to outer bolts. Verify all bolts are torqued properly.
    Torque spec

    Intake Manifold Bolts25 Nm (18 lb-ft)
13. 13

    Reinstall Support Brackets and Components
    Reinstall intake manifold support brackets and torque mounting bolts to 47 Nm (35 lb-ft). If equipped with EGR valve, install new EGR gasket and reinstall EGR valve, torquing bolts to 25 Nm (18 lb-ft). Reconnect EGR electrical connector.
14. 14

    Reinstall Fuel Rail and PCV System
    Remove shop towels from injector ports. Lubricate injector o-rings with clean engine oil. Carefully press fuel rail with injectors into intake manifold ports, ensuring all injectors seat properly. Install fuel rail bolts and torque to 12 Nm (9 lb-ft). Reconnect all fuel injector connectors and fuel pressure sensor. Reconnect fuel feed line until it clicks. Install PCV valve into valve cover, torquing to 8 Nm (6 lb-ft) if threaded type. Reconnect PCV hose to intake manifold.
    Torque spec

    Fuel Rail Bolts12 Nm (9 lb-ft)
15. 15

    Reinstall Throttle Body and Complete Assembly
    Remove shop towel from throttle body opening. Install new throttle body gasket. Position throttle body and install bolts, torquing to 10 Nm (7 lb-ft). Reconnect throttle body electrical connector. Reconnect coolant bypass hoses and secure with clamps. If equipped, install coolant crossover and torque bolts to 15 Nm (11 lb-ft). Reconnect all vacuum lines to proper locations per reference photos. Install air intake assembly and tighten clamp. Reconnect mass airflow sensor connector.
    Torque spec

    Throttle Body Bolts10 Nm (7 lb-ft)

Reassembly

1. Refill cooling system with Toyota Super Long Life Coolant (Pink) to proper level in reservoir
2. Reinstall fuel pump relay
3. Reconnect negative battery terminal
4. Reinstall engine cover by aligning front clips first, then pressing down on rear until clips engage
5. Double-check all electrical connectors, vacuum lines, and hoses are properly connected
6. Verify no tools or shop towels were left in engine bay

Verification

• Start engine and allow to idle. Listen for any vacuum leaks (hissing sounds) around intake manifold
• Check for fuel leaks at fuel rail connections while engine is running
• Check for coolant leaks at throttle body and crossover connections
• Verify engine idles smoothly with no rough running or stumbling
• Rev engine gently and verify smooth acceleration with no hesitation
• Allow engine to reach operating temperature and verify cooling system has no leaks or air pockets
• Check engine for diagnostic trouble codes using OBD-II scanner. No codes should be present
• Test drive vehicle to verify normal operation under load with no loss of power or check engine light

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