Toyota Chassis and Body workshop and repair manual
Toyota Land Cruiser - Chassis and Body factory workshop and repair manual Covers FJ40,FJ43, FJ45, FJ60, BJ40, BJ 42, BJ43, BJ45, BJ46, BJ60 series and HJ47 and HJ60 series
on PDF can be viewed using PDF reader like adobe , or foxit or nitro
File size 120 Mb Bookmarketed with 851 pages
1980 publication . Does not cover the engine. Covers Clutch, transmission (4 speed H41 and H42 and 3 speed J30),transfer case,propeller shaft, front and rear axles,steering,brakes,winch,frame,body and electrical.
What you’re fixing: the air intake tube (sometimes called intake duct, snorkel, or intake hose) — the rubber/plastic tube that routes filtered air from the airbox to the throttle body on a Toyota. Below is a beginner-friendly, step‑by‑step explanation of every component, why this repair is needed, how the system works, what can go wrong, and how to replace/repair the tube safely and correctly.
OVERVIEW / ANALOGY
- Think of the engine as a person breathing: the airbox + air filter is the nose (cleaning the air), the intake tube is the windpipe, the MAF/IAT sensors are the oxygen/flow sensors in the windpipe that tell the brain (ECU) how much air is coming in, and the throttle body is the vocal cords that control airflow into the lungs (cylinders).
- If the windpipe leaks, is pinched or clogged, the “person” breathes wrong — poor power, rough idle, check engine light.
COMPONENTS (what every part is and what it does)
1. Air filter (inside airbox)
- Paper/foam element that traps dirt and debris.
- Protects engine internals and sensors.
2. Airbox (plastic housing)
- Holds the air filter and forms a sealed chamber.
- Often has mounts, seals, and a cover held by clips/bolts.
3. Intake tube / intake hose / snorkel
- Flexible rubber or plastic tube connecting airbox to throttle body.
- May include ribs and a resonator chamber to reduce noise.
- May have integrated branches for PCV/evap or sensor ports.
4. Clamps and band clamps
- Worm-gear or ear-style clamps that hold the tube to the airbox and throttle body.
- Ensure airtight seals.
5. Mass Air Flow (MAF) sensor (if equipped)
- Measures amount of air entering the engine, often mounted in the airbox or tube.
- Very sensitive — has a hot wire or film.
6. Intake Air Temperature (IAT) sensor (often integrated with MAF or mounted in tube)
- Measures incoming air temperature for ECU calculations.
7. PCV/crankcase breather hose
- Allows crankcase gases to be routed into intake for combustion.
- Usually connects to the intake tube or throttle body.
8. Vacuum lines / breather hoses / EVAP hoses
- Small hoses that connect to ports on the intake piping.
- Control emissions and other systems.
9. Throttle body
- The downstream connector on the engine where the tube meets the intake manifold.
THEORY — why this matters
- Engines need a precise amount of clean air to mix with fuel. The ECU uses sensor data (primarily the MAF and sometimes MAP/IAT/oxygen sensors) to meter fuel.
- The intake tube must deliver air without leaks, restrictions, or contamination of sensors. If air enters downstream of the MAF (an unmetered leak), the ECU thinks less air is present and injects less fuel → lean condition → misfires, hesitation, rough idle, or limp mode.
- A cracked or collapsed tube can also restrict flow during heavy throttle, reducing power.
- Contaminants or oil on the MAF can cause incorrect readings and incorrect fueling.
SYMPTOMS OF A BAD INTAKE TUBE
- Check Engine Light (codes P0171/P0174 lean, MAF codes, or random misfires)
- Rough idle, stalling, hesitation or poor throttle response
- Reduced acceleration/power
- Whistling or hissing sounds (air leaks)
- Visible cracks, splits, or collapsed sections in the hose
TOOLS & PARTS YOU’LL NEED
- New intake tube (OEM or quality aftermarket), replacement clamps if old
- New air filter if old/dirty
- Screwdrivers (flat & Phillips) or 1/4" socket for hose clamps
- Ratchet and socket set (usually 8mm, 10mm)
- Pliers for clips
- Clean rags and gloves
- MAF cleaner spray (if you will clean MAF)
- Small flat blade for prying seals (careful)
- OBD-II scanner (helpful to read/clear codes)
- Optional: dielectric grease (for electrical connectors), silicone spray (for easier installation)
Safety: work on a cool engine, wear gloves/eye protection. When handling MAF, disconnect battery negative to avoid accidental codes — but it’s not always necessary; at least remove connector before touching.
STEP‑BY‑STEP — remove, inspect, replace, reinstall
1. Preparation
- Park on level ground, set parking brake, engine cool.
- Disconnect negative battery terminal if you’re going to unplug the MAF sensor or work with electrical connectors (optional but safe).
- Locate the airbox and intake tube: usually a plastic box (near front) and a hose to the throttle body.
2. Remove the airbox cover & air filter (if needed)
- Unclip or remove fasteners holding the airbox lid.
- Remove the air filter — inspect for dirt, replace if dirty.
3. Disconnect sensors & small hoses
- Unplug MAF electrical connector (press tab and pull straight back).
- Remove any vacuum/PCV hoses connected to the intake tube — note their positions (take a photo if unsure). These are usually pulled off or held with small spring clamps.
- Remove any bracket bolts attaching tube to chassis.
4. Loosen clamps
- Use screwdriver or socket to loosen clamps at both ends of the intake tube (airbox side and throttle body side). Loosen clamps enough to slide them back.
5. Remove the intake tube
- Pull the tube straight off; twist gently to break the seal if it’s stuck. Inspect ends for torn rubber or missing seals.
- Inspect tube for cracks, holes, melted spots, or collapsed sections. Flex the tube to find hidden cracks. If it smells of oil or has greasy deposits, that can indicate PCV blow-by and possible contamination of MAF.
6. Inspect MAF & sensors
- If MAF is in the airbox/tube, inspect it for dirt and contamination. Do NOT touch the sensor element.
- If slightly dirty, use MAF cleaner spray: hold the sensor and spray the element with the cleaner, let it air dry completely. Do not use compressed air or rag.
- Also inspect IAT sensor if present.
7. Inspect mating surfaces & clamps
- Check throttle body bore for dirt. Wipe away grime from the mating area.
- Inspect seals/gaskets on the airbox and throttle body lip. Replace if brittle.
8. Install the new tube
- Slide the tube onto the throttle body and airbox with clamps loosely on the tube. Align vacuum/PCV ports so hoses can reach without kinking.
- Reconnect vacuum lines and PCV breather hoses. Replace any brittle hoses.
- Reconnect the MAF/IAT electrical connector (make sure the connector clicks).
- Position clamps evenly — tighten them snugly but do not over-tighten (plastic ends can crack). Aim for firm, fully seated clamp; don’t strip the worm gear or crush the tube. If using ear clamps, crimp according to manufacturer spec.
9. Reinstall airbox and filter
- Make sure filter is seated correctly, airbox lid fastened securely, and any intake snorkel in front is connected.
10. Final checks and start
- Reconnect the negative battery if disconnected.
- Start engine, let idle. Listen for whistles or hisses.
- If you have an OBD-II scanner, check for active trouble codes and clear them if appropriate. A cleared code may return if the issue persists.
- To test for leaks: with engine idling, lightly spray carb cleaner or soapy water around clamp seams; if RPM changes or bubbles form, there’s a leak. Alternatively, use a smoke tester if available.
COMMON PROBLEMS & TROUBLESHOOTING
- Cracked tube/holes: fix by replacing the tube. Temporary patches (tape/epoxy) can fail and cause unmetered air.
- Collapsed or pinched section: replace — collapsible sections restrict airflow under load.
- Loose clamps: tighten/replace clamps. A loose clamp allows unmetered air.
- Detached PCV hose: causes rough idle and codes. Reattach or replace hose.
- MAF contamination: causes poor fueling. Clean MAF with specific cleaner or replace if damaged.
- Wrong routing of hoses after reassembly: reconnect exactly as before. Misrouted hoses cause vacuum leaks or restrictions.
- Over-tightening clamps/cracking brittle plastic: tighten snugly only. Replace brittle plastic parts if cracked.
TIPS FOR DURABILITY & PREVENTION
- Replace old rubber hoses and clamps when replacing the tube.
- Inspect air filter regularly; a dirty filter can lead to oilier intake and MAF contamination.
- Use OEM-style replacement tubes where possible — aftermarket may have different fit or port placement.
- After repair, drive the car and recheck for codes; some codes require a drive cycle to clear.
- If you still have drivability problems after replacing the tube, scan for codes and test for intake manifold leaks, vacuum leaks, or fuel system issues.
QUICK CHECKLIST BEFORE YOU Leave the Job
- All clamps snug, not cross-threaded or over-tightened
- Vacuum/PCV hoses attached and routed correctly
- MAF connector clean, connected, and locked
- Air filter installed and airbox sealed
- No tools or rags left in engine bay
What can go wrong if you ignore it
- Continued poor fuel economy and power loss
- Engine misfires, failed emission tests, catalytic converter damage
- Persistent check engine light and possible limp-home mode
- Long-term MAF damage from contaminants
That’s the complete beginner-friendly walkthrough: what each part does, why you repair the intake tube, step-by-step removal and replacement, diagnostic tips, and common failure modes. Follow the steps, handle sensors carefully, and replace any brittle hoses or damaged clamps while you’re in there. rteeqp73
Time running out for free repair of rusting Toyota frames Time running out for free repair of rusting Toyota frames.
TOYOTA LAND CRUISER | Body and Chassis | Toyota This video explains body and chassis as well as user benefits from them. #Toyota #ToyotaGlobal #ToyotaLANDCRUISER Toyota ...
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