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Toyota 4Runner 1996-2002 factory workshop and repair manual download

Purpose: safe, beginner-friendly guide to access, inspect, clean, and (if needed) replace the air filter and housing components on a Toyota 4Runner. Follow each bullet; no assumptions about prior experience.

Safety and preparation
- Park on a level surface, set parking brake, turn engine off and remove key. Allow engine to cool if recently run.
- Wear safety glasses and gloves to keep hands clean and protect from dust and sharp edges.
- Work in a well-lit area; keep a rag or paper towels and a small bucket handy for debris.

Tools — detailed descriptions and how to use each
- Flat-head screwdriver (short and medium shaft)
- Description: single flat blade in a handle. Useful for prying open plastic clips or levering the airbox cover.
- How to use: place blade under the edge of a plastic clip or tab and gently twist or pry upward until the clip releases. Use controlled force to avoid cracking plastic.
- Phillips screwdriver (cross-head)
- Description: cross-shaped tip for Phillips-head screws.
- How to use: hold screwdriver straight into screw, apply firm downward pressure, and turn clockwise to tighten or counterclockwise to loosen. Use the correct size to avoid stripping heads.
- Socket wrench (ratchet) with 10 mm socket
- Description: ratcheting handle with a removable 10 mm socket—common for 4Runner airbox bolts/clamps.
- How to use: place socket over bolt head, pull handle to break bolt loose, then use ratchet motion to remove. Use a short extension if access is tight. Reverse to reinstall, snug but don’t over-torque plastic fasteners.
- 1/4" or 3/8" extension (optional)
- Description: metal shaft that extends the reach of a socket wrench.
- Why required: helps reach bolts recessed deep in the airbox area.
- How to use: attach between ratchet and socket; use same ratchet motion.
- Pliers (needle-nose or slip-joint)
- Description: jawed hand tool for gripping small parts like hose clamps or stubborn clips.
- How to use: squeeze handles to close jaws around clip or clamp, pull or twist to remove. Use needle-nose for narrow spaces.
- Trim/clip pliers (optional but helpful)
- Description: pliers shaped to pull plastic trim clips without breaking them.
- Why required: preserves plastic clips and makes removal easier.
- How to use: slide under clip head and leverage outward until clip releases.
- Clean shop rag or microfiber towel
- Description: lint-free cloth to wipe dirt and seal surfaces.
- How to use: wipe inside housing and mating surfaces after removing debris.
- Shop vacuum or small hand vacuum (optional but recommended)
- Description: vacuum to remove loose debris from the airbox and intake snorkel.
- Why required: ensures no debris falls into intake when reinstalling filter.
- How to use: vacuum inside the airbox, corners, and snorkel opening.
- New air filter element (replacement part)
- Description: paper/pleated filter sized for your 4Runner’s year and engine. OEM or aftermarket compatible.
- How to use: seat it into the housing with the rubber sealing lip aligned; do not force.
- Replacement clips, screws, or airbox assembly (if damaged)
- Description: plastic fasteners, 10 mm bolts, or full airbox cover if cracked.
- Why required: damaged clips or cracked housing can allow unfiltered air; replace with OEM or equivalent parts.
- Disposable gloves (optional)
- Description: protects hands from dirt/oil.
- How to use: wear while handling old filter and cleaning.

Procedure — accessing and servicing the air filter housing
- Open the hood and locate the air filter housing: a large rectangular plastic box on the passenger side of the engine bay with an intake snorkel running to the front.
- Identify how the cover is secured: commonly a combination of metal screws/bolts, plastic clips, or clamps. Note locations visually before touching.
- Disconnect intake snorkel or mass airflow sensor wiring if it obstructs the cover removal
- Locate the MAF sensor plug (if present) and depress its tab, pulling the connector straight out. Set aside gently.
- Loosen any hose clamp connecting snorkel to the airbox using flat-head screwdriver or nut driver.
- Remove cover fasteners
- Use trim pliers or flat-head screwdriver to pop plastic clips: pry gently under the clip head and lift.
- Use 10 mm socket on ratchet for bolts: turn counterclockwise until free and store bolts in a clean place.
- If Phillips screws are present, use the Phillips screwdriver to remove.
- Lift the airbox cover straight up; wiggle gently if stuck. Do not force at an angle that stresses plastic tabs.
- Remove the old air filter element
- Note orientation of filter (rubber lip up/down) so you reinstall correctly.
- Pull filter straight out; inspect for excessive oil, heavy soot, or large debris.
- Inspect the inside of the housing and snorkel
- Check for leaves, twigs, rodents’ nest, oil, or excessive dust.
- Run a hand (gloved) around the mating surfaces to feel for cracks or warped sealing surfaces.
- Vacuum out loose debris; wipe mating surfaces with a clean rag to ensure a good seal.
- Inspect the filter sealing surface and gasket
- Ensure the rubber gasket on the new/old filter isn’t torn, flattened, or missing.
- If gasket damaged, the filter will not seal; replace filter.
- Install new or cleaned filter
- If reusing the old filter (only if lightly dirty and dry), tap out large debris and vacuum pleats. Replace if doubt.
- Place the new filter into the lower housing with the rubber lip seated fully into the recess. Ensure correct orientation.
- Re-seat the cover and reattach fasteners
- Lower cover straight down so it seats evenly; press clips back in until they engage or reinstall bolts/screws.
- Tighten 10 mm bolts until snug. Do not over-tighten plastic bolts—snug is sufficient to prevent air leaks.
- Reconnect snorkel hose clamp and MAF electrical connector.
- Final checks
- Tug lightly on the cover to confirm it’s secure and sealed.
- Start engine and listen for hissing or air leaks around the airbox. Re-inspect if unusual noise appears.

When replacement is required and why
- Air filter element replacement
- Why: filters trap dust and debris; when clogged, they reduce engine airflow, lower fuel economy, decrease performance, and can stress the MAF sensor.
- What to buy: filter specific to your 4Runner’s year and engine (e.g., 4.0L V6 vs 2.7L I4). Use OEM part number from owner's manual or equivalent brand (AEM, K&N, Purolator, FRAM). If unsure, supply year/engine to parts retailer or match by old filter shape/size.
- Broken or cracked airbox cover/housing
- Why: cracks permit unfiltered air and contaminants to enter the engine; also may prevent proper filter sealing.
- What to buy: replacement cover or full housing assembly (OEM part or quality aftermarket). You can often replace just the cover if lower housing is intact.
- Missing or damaged clips/fasteners
- Why: loose or missing fasteners allow the cover to vibrate or not seal.
- What to buy: plastic clip kits, replacement screws or bolts (often 10 mm bolts for Toyota).
- Damaged snorkel, intake resonator, or mass airflow sensor
- Why: holes or cracks allow unfiltered air; a contaminated or faulty MAF causes poor performance.
- What to buy: replacement snorkel/resonator or MAF sensor (MAF usually replaced only if diagnostic trouble codes or sensor failure). Clean MAF with MAF cleaner if lightly contaminated—do not touch sensing element with fingers.

Notes for beginners and troubleshooting
- If fasteners are stiff, apply penetrating spray to bolts, wait a few minutes, then try again.
- Keep track of removed parts in a small tray or magnetic dish so nothing falls into the engine bay.
- Never use compressed air directly on a paper filter; it can damage the pleats. Replace if heavily soiled.
- Avoid petroleum-based cleaners in the airbox; water or mild detergent for heavy oily contamination, thoroughly dry before reinstalling.
- If you hear a new whistling or suction noise after reassembly, recheck seals and fasteners — likely a clip not fully engaged or a mis-seated filter.

Disposal and maintenance interval
- Dispose of the old paper filter per local regulations (usually household waste).
- Typical replacement interval: every 12,000–30,000 miles depending on driving conditions (dusty/off-road shorter interval). Replace sooner if visibly dirty.

End.
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