This procedure covers removal and replacement of the intake manifold on the 2019-2024 Toyota RAV4 2.5L I4 gas engine, including disconnection of related sensors, hoses, and throttle body.

Warnings

Tools required

Parts

• Intake manifold gasket set × 1 — Use OEM specification
• Throttle body gasket × 1 — Use OEM specification
• PCV valve grommet (if damaged) × 1 — Use OEM specification
• Vacuum hose clips (as needed) × 1 — Use OEM specification

Fluids

• Toyota Super Long Life Coolant (Pink) — 1 qt

Preparation

1. Ensure engine is completely cool to the touch (minimum 2 hours after last operation)
2. Disconnect negative battery terminal and wait 5 minutes for airbag system to discharge
3. Remove engine cover by pulling upward on front clips and lifting
4. Place drain pan under vehicle and drain approximately 1 quart of coolant from radiator drain cock to level below intake manifold
5. Relieve fuel system pressure if fuel rail must be disturbed (not typical for this job)
6. Photograph all electrical connector positions and vacuum hose routing for reference during reassembly

Procedure

1. 1

   Disconnect air intake system
   Loosen clamp at throttle body inlet and disconnect mass air flow sensor electrical connector. Remove air intake tube and air filter housing assembly. Set aside to provide access to top of engine.
2. 2

   Remove throttle body
   Disconnect throttle body electrical connector. Remove four throttle body mounting bolts using 10mm socket. Carefully pull throttle body away from intake manifold. Inspect gasket and replace if damaged. Cover throttle body opening with clean shop rag to prevent debris entry.
   ⚠Do not allow dirt or debris to enter throttle body bore or intake manifold opening.
   Torque spec

   Throttle Body Bolts10 Nm (7 lb-ft)
3. 3

   Disconnect vacuum hoses and coolant lines
   Disconnect brake booster vacuum hose from intake manifold. Disconnect PCV hose from valve cover. Disconnect EVAP purge valve line if attached to manifold. Disconnect coolant bypass hoses from rear of intake manifold (if equipped) using hose clamp pliers. Be prepared for coolant spillage.
   ⚠Label all vacuum hoses during removal to ensure correct reconnection. Incorrect routing will cause driveability issues.
4. 4

   Disconnect electrical connectors
   Disconnect all electrical connectors attached to intake manifold including: fuel injector connectors (if fuel rail is attached to manifold), intake manifold runner control solenoid (if equipped), and any temperature or pressure sensors mounted on manifold. Press release tabs fully before pulling connectors.
5. 5

   Remove fuel rail (if necessary)
   If fuel rail is attached to intake manifold on this engine configuration, disconnect fuel supply line at rail. Remove fuel rail mounting bolts and carefully lift rail with injectors straight up and out. Plug injector ports in manifold immediately with clean rags to prevent debris entry. Secure fuel rail assembly away from work area.
   ⚠️Fuel system may still contain pressure. Have fire extinguisher nearby and avoid ignition sources.
   Torque spec

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

   Remove PCV valve
   Remove PCV valve from valve cover or intake manifold using appropriate socket. Inspect valve for proper operation by shaking - it should rattle freely. Replace if stuck or clogged.
   Torque spec

   PCV Valve8 Nm (6 lb-ft)
7. 7

   Remove intake manifold mounting bolts
   Remove all intake manifold mounting bolts in reverse order from tightening sequence (outside-in pattern). There are typically 8-10 bolts securing manifold to cylinder head. Use 12mm or 14mm socket as needed. Keep bolts organized in order for reinstallation.
   ℹ️Note the location of any different length bolts. Some positions may use longer bolts for brackets or ground straps.
8. 8

   Remove intake manifold
   Carefully lift intake manifold straight up and away from cylinder head. Manifold may require gentle prying if gasket is stuck - use plastic pry tool at designated pry points only. Never pry between mating surfaces. Once free, cover intake ports on cylinder head immediately with clean rags or tape.
   ⚠️Absolutely no debris, fasteners, or tools can fall into open intake ports. This will cause catastrophic engine damage.
9. 9

   Clean mating surfaces
   Remove old gasket material from intake manifold and cylinder head mating surfaces using plastic gasket scraper. Do not use metal scrapers that could gouge aluminum surfaces. Clean surfaces with brake cleaner and lint-free shop rags. Surfaces must be completely clean and dry. Inspect manifold for cracks or warping.
   ⚠Keep all debris and gasket material out of intake ports. Vacuum or wipe away from ports, never toward them.
10. 10

    Install new gaskets and position manifold
    Install new intake manifold gaskets on cylinder head, aligning all port openings exactly. Some gaskets have alignment pins or tabs. Remove protective covering from intake ports. Carefully lower new or cleaned intake manifold onto gaskets, ensuring all ports align properly and gaskets do not shift.
11. 11

    Install and torque manifold bolts
    Hand-thread all intake manifold bolts into position. Verify all bolts are correct length for their positions. Using torque wrench, tighten bolts to specification in proper sequence (center-out pattern) as specified in service manual. Make two passes: first to 50% torque, second to final specification.
    ⚠Critical: Tighten in center-out sequence to prevent warping. Verify exact sequence diagram in factory service manual before tightening.
    Torque spec

    Intake Manifold Bolts25 Nm (18 lb-ft)
12. 12

    Reinstall PCV valve and fuel rail
    Install PCV valve with new grommet if needed, torquing to specification. If fuel rail was removed, install new injector o-rings, lubricate with clean engine oil, and carefully press fuel rail assembly into position. Install fuel rail bolts and torque to specification per service manual sequence.
    Torque spec

    PCV Valve8 Nm (6 lb-ft)

    Fuel Rail Bolts12 Nm (9 lb-ft)
13. 13

    Reconnect all hoses and electrical connections
    Reconnect all electrical connectors to sensors and injectors, ensuring positive clicks. Reconnect all vacuum hoses per photographs taken during disassembly. Reconnect coolant bypass hoses with new clamps if originals are damaged. Reconnect fuel supply line to fuel rail.
14. 14

    Reinstall throttle body
    Install new throttle body gasket on intake manifold. Position throttle body and hand-thread all four bolts. Torque bolts to specification in cross pattern. Reconnect throttle body electrical connector.
    Torque spec

    Throttle Body Bolts10 Nm (7 lb-ft)
15. 15

    Reinstall air intake system
    Reinstall air filter housing and intake tube. Reconnect mass air flow sensor connector. Tighten intake tube clamp at throttle body. Refill cooling system to proper level with Toyota Super Long Life Coolant (Pink). Reconnect negative battery terminal.

Reassembly

1. Double-check that all electrical connectors are fully seated and locked
2. Verify all vacuum hoses are routed correctly and secured with clips
3. Ensure no tools or rags are left in engine bay
4. Check that all bolts are installed and properly torqued
5. Verify coolant level is correct before starting engine

Verification

• Turn ignition to ON position (do not start) and check for fuel leaks at fuel rail and supply line connections
• Start engine and allow to idle. Check for vacuum leaks by listening for hissing sounds around intake manifold mating surfaces
• Verify smooth idle with no rough running or misfires. Check engine codes with scan tool - there should be no new codes
• Check for coolant leaks at bypass hose connections after engine reaches operating temperature
• Test drive vehicle to verify normal acceleration and no hesitation or stumbling under load
• Recheck all fastener torques after initial heat cycle if performing critical repair

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