Intake Manifold Gasket Replacement and SAIS filter swap procedure 2UZ-FE Lexus GX470 Toyota 4Runner
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- เผยแพร่เมื่อ 22 ส.ค. 2024
- This video is about Secondary Air Injection (SAIS) filter swap procedure and intake manifold gasket replacement procedure to fix a very slow coolant leak. The video also briefly demonstrates cleaning of the throttle body. This may be a great time to inspect, clean and replace the PCV valve if necessary. I have inspected and cleaned mine with throttle body cleaner, but the footage was lost, my apologies. I hope you find this video somewhat informative on how to perform such a procedure. This video only describes my experience and is not meant to be instructional. Thank you for watching!
Please leave a comment below if you have questions about the procedure or maybe have comments or suggestions on how I could improve this procedure.
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This video is better than any professional trade school videos. Truly it’s the beauty of the University of TH-cam at its best, fast, to the point, clear and informative. Today I was successful in removing my intake plenum. Thank you
Thank you for watching, Mr. Richardson. I appreciate your kind words. Hindsight, I have not replaced the o-ring on the coolant pipe towards the rear of the driver’s side coolant pipe bridge, and the leak is back. I will need to tear into it yet again, 2 years later and replace that o-ring. When I do, I will record and post a video of this procedure yet again. Stay tuned!
Everyone already said exactly what I wanted to say….. OUTSTANDING tutorial and thank you for teaching.
Thank you very much for your comment! It means a lot!
Man this is exactly what I needed to find. Thanks for taking the time to put this up. Subbed.
Byron, I found out that the problem with the leak was not the intake manifold, it was the water bypass gasket in the very back up against the firewall, I am currently in the process of replacing that and the videos will be coming out in the next couple weeks. In the meantime, check out my shorts videos as I am documenting my progress.
Thank you for subbing!
Amazing video man, thank you so much!!! About to change a knock sensor on an '06 GX470 and I need to take off the intake manifold to get to it.
Thanks, Jacob! Glad you found it useful! Depending on how many miles you have in yours, You may want to consider replacing the starter and some vacuum hoses if they are getting brittle while you’re there.
@@MaximumDIYGarage Great idea. Its my cousins car, I'm not sure how many miles but its definitely over 100k. Is there any specific "hard" lines I need to buy or am I good to buy general use line and cut it all to fit while I'm in there?
@@dirtbikejaydolla that I do not recall. I didn’t replace any on the GX, but I did on the XTerra recently. I have a short teaser on my channel. (Full video coming out soon).
Did you end up doing the knock sensor yourself? I'm planning to do it and looking for any helpful material/resources. Please do share if you've got something useful. Thanks!
I have not replaced the knock sensor, Salman.
EXCELLENT video, with complete attention to pointing out the details. Very well done! I'll refer this video when the need arises!
I’ve never thought I would ever say this, but thank you Maestro Devil, lol
Check out my spark plug replacement video: th-cam.com/video/FLpE8L5Yx5A/w-d-xo.html
Great video!! Glad you put all the specific details in this video...I'll surely use this if/when I need to replace my gaskets!
@Awesomoto: the intake manifold gasket is not a very common issue in GX’s, but SAIS failure is. It’s good to address the SAIS filter while you’re there doing the gasket. This step extends life of the air pump and the entire SAIS. Kind of like when you do your water pump, you should replace the timing belt and vice versa. Enjoy your GX. The 120-series platform is shared among the FJ Cruiser, 4Runner and GX470, but the GX is the best riding and with the most bells and whistles of the three. And like you’ve mentioned the 2UZ is one of the best engines Toyota has ever made!
Thank you for this!!! Your tutorial will help me replace the knock sensors and knock sensor harness on my 04 gx470.
@Calvin Tran: you are welcome, sir! I am glad you found it helpful! Be well!
Thanks for the video and for including the torque specs and other recommendations and details...!
@TC: you are welcome! I’m glad you found it helpful.
Good job bro! Thanks!
Thank you for watching!
I don’t even own this car but appreciate your video
Glad you liked it, Steve!
I have a few more in my channel on 2nd gen Honda CR-V maintenance/fluid refresh and break-in oil change on a Mitsubishi Outlander. Oh, also a barn find 1997 Celica GT restoration project. Check it out if you have a moment. Thanks for watching! Have an awesome weekend!
Oh yes, I just bought an 06 XTerra with a manual trans to restore. Videos coming out soon!
I have a leak coming from the rear and think it in this area.
I'm confused about your leak. The intake manifold seal isn't a coolant area, but yours had red everywhere.
What did you repair to stop the leak? The rear bypass gaskets (qty2)??
Yes, you are correct - it’s rear bypass gaskets X 2. A video is coming soon!
Great video! Very helpful.
I’m glad I could help
Did the filter touch that pipe? I just put one on and it slightly touched the pipe?
Yes, that should be fine
Job done, just copy you 🙏
Good job!!!
If the foam piece gets sucked in and it's no longer seen during disassembly.... what to do? Do we have to replace the whole system or is the foam pieces sucked into the engine?
That is a million dollar question, isn’t it. It has been over 4 years since I have discovered my foam piece was missing and my SAIS system is working properly. It certainly it has a potential for failure and ruining the system, however, I am not aware of any cases that it could ruin the engine. I think you have two choices: 1) pray that it is not going to do any damage; and 2) trade up for a much newer GX460 with a better access to the filter and replace it while it is still intact with an external filter. If your truck goes into limp mode then the SAIS system is toast and you have two choices: replace the system ($3,000), or buy a bypass kit ($300) but the second option may seem your truck unable to pass emissions testing, so chose wisely and according to local laws and regulations.
@@MaximumDIYGarage I checked on some community forums and it seems like this air pump is to the exhaust, not involved in any part of the engine operation, and is related to emission requirements, so if the foam falls in I don't think it's the end of the world. Maybe it'll get melted and burned out in the exhaust.
"The AIP system was introduced to the 100 series in 2006. I believe Tundras and possibly Sequoia's received in in 2005. It's an emissions system and has absolutely nothing to do with the function of the engine. The sole purpose of this is to introduce additional oxygen into the exhaust on a cold start in order to heat up your catalytic converter faster.
It only runs when the coolant is below 104 degrees and the air temp is above 40 degrees. When it does run, it's only for a few minutes until everything heats up. It pumps air from up near the intake into the exhaust where the manifold leaves the engine block."
Right, except that if the SAIS gets clogged with foam particles, the truck is going to limp mode, which makes it unsafe for highway travel and the system either needs to be replaced or bypassed depending on your local regulations.
Thanks for posting your response!
WoW, I am not mechanically inclined but I Think I can do this. Awesome video, felt like a Lexus how-to tutorial. I will have to subscribe and check if you have videos for the water pump, timing belt and pulleys I keep hearing I need to change. I was just gifted a 2003 GX with 189K miles so I need to get on this. Would it be smart to just replace the SAIS anyway? Is it hard or easy to replace those plastic pieces? What else do you recommend once we are in that area?
Thank you for your comment! First of all, congratulations! You now have one of the greatest on and off road machines ever made! I have not done the timing belt/water pump on my GX as it was done by a previous owner already. I have done this job on my Celica, however, and must admit it is a difficult job that may take a couple of days for someone who has never done it before. Most people prefer to pay $1,200 at a local Lexus dealer. I recommend a Toyota service dept as it is a bit cheaper, or if you have a trusty mechanic who has worked on Toyota/lexus trucks before. As for replacing SAIS, I would not worry about as long as it is working. It is a very expensive system to replace and involves a lot of labor, but is not fatal to the engine if it fails compared to timing belt failure.
If you do decide to replace SAIS, you may want to replace a starter as well because of its location right there in the valley of the V8 next to SAIS.
I will be posting the timing belt replacement on my Celica soon, so stay tuned. Thanks for subscribing! And enjoy your GX! Your truck has a huge advantage over the 2004- and older because it has a true transmission fluid dipstick- so much easier to replace the fluid!
Excellent video! Makes want to trade in my accord for a used GX
@Rigo Trujillo: Thank you Rigo! Honda Accord is a great car. What year is yours? Is it a coupe or a sedan? The GX is definitely a great vehicle, but not for every lifestyle. Unless you have a family with children who can use 5-7 seats, if you tow a trailer (jet skis, snowmobile or other toys) or a camper or need high ground clearance with excellent off road capability, the GX is not the most efficient everyday commuter vehicle. If you would consider getting it as a second vehicle in the family or use it as a weekend cruiser or a vacation/adventure vehicle, you will not find too many that can match its capabilities (unless you stick with land cruisers, 4Runners and FJ Cruisers) ,legendary reliability and resale value.
Used GXs (470s in particular) are getting quite affordable, so you may want to start looking for one! Depending on your budget, you may pick up one as low as $5k with over 200k miles on it. I would go for the newest model you can afford, regardless of mileage, as long as it has had proper maintenance !!!
@@MaximumDIYGarage That would be a great price and maybe they should cost that much but they are going or over 12K for that many miles, I guess it depends on where you live and pre covid pricing.
Jim, you are right. When I made my original post a year ago, the prices were still decent. Today, you can’t touch one with 150-200k for less than $10-$12k! They are getting so popular, plus the used car market prices have been crazy high!
I’m confused what’s the difference between the filter for the secondary air injection versus the bypass kit that Hewitt or roush is offering?
Hi! The breather filter I installed is meant to be used on a functioning system to prevent the aged original foam filter from destroying the SAIS. Once the filter particles clog the valve(s), pump or passageways, you will get a Christmas tree on your dash and your truck goes into limp mode. This where you have two choices - pay up to $2,000 for replacement of the SAIS components or get a bypass module from the mentioned above companies. Be careful though, if you live in a state or a city that requires annual emissions inspection, your truck may not pass due to the bypass installed. Remember, the SAIS only runs the first 30 seconds after the start of the engine to minimize carbon pollution when the cats haven’t been up to temp, and of course, the emissions inspection checks the exhaust at start up, so this is where they may fail you. I hope my explanation makes sense.
So if you already have a malfunctioning SAIS, it’s too late to install the breather filter. You may want to put one on the new unit if you are replacing your system or install one on a functioning system as a preventative maintenance, like I did.
Intake manifold doesn’t have coolant flow, it was the heater hose/crossover pipe that was leaking. Learned the hard way? Hopefully you caught it and just didn’t show
Dennis, you are spot on! I thought I “fixed” the problem, however I’m slowly losing coolant again, and it’s coming exactly from where you are saying, the vertical coolant pipe connection. I suspect the O-ring needs to be replaced.
I will be doing this repair next. At least now I know how to tear it apart and put back together quickly. Maybe should replace the starter this time as preventative maintenance?
@@MaximumDIYGarage pull the manifold and pressure test it. You can rent the pressure tester if you don’t have one. It could definitely be the pipe, but I think it’s press fit not o-ring. but more likely just the gasket is leaking. Keep us posted 🤙🏼
@@DiagnosticDennis will do, Dennis! Thanks again! I’ll upload a video once I complete the repair. I don’t drive the GX every day, so that project is on a back burner. I just blew a radiator or a coolant line in my 06 XTerra, so need to address that first.
@@MaximumDIYGarage I think I have a similar leak, it's coming down from rear of engine somewhere, and drips off transmission housing onto the skid plate, then onto the ground. It's a very slow leak, I've only replaced fluid one time since I noticed it (4 months ago). So you have to take off this housing (intake ?) again to get to the heater hose crossover pipe? What a pain... maybe I'll replace the same gaskets you did and the filter while I'm in there... and hope the starter lasts forever. LOL. I have 210k miles.
Hi Brian! Yes, unfortunately, you have to remove the intake manifold to get to the cooling pipes. Good idea to replace the vacuum hoses and the rest of the brittle rubber hoses and PCV valve while you’re there. The starters are known to last 300+k miles without issues, so I wouldn’t worry about it. Good for you for having 210k miles! I only have 125k on mine. Keep us posted on your progress!
beautiful
Thank you sir!
Great vid! I saw on your ih8mud post that you had a coolant leak come back up a few months after this job. Did you ever figure out where it was from?
Hi Jim! I’m not sure what it was, but it has sealed itself and I had no measurable loss of coolant since. If you’re having the problem, check the O-ring on the crossover coolant pipe. Sometime that one seeps coolant on the driver side.
@@MaximumDIYGarage Thanks for your response! I actually replaced the oring going into the front crossover pipe while replacing the front and rear crossover pipe gaskets (as well as starter, etc...) I found some dried coolant near the pipe going into the front crossover, but doesn't seem to be active now? I'm hoping that the leak was from the oring before it fully sealed as the coolant system fully pressurized. I figure that if it was leaking due to a rolled or damaged oring it would be pretty apparent.
That’s what mine did, I think! Great job! Looks like your truck is ready for another 20 years of impeccable service! Just keep her rust-free!
@@MaximumDIYGarage 🤞🤞 Let's hope so! The thought of doing this job again in my parking lot to get to one oring can bring a man to tears 😂😂😂 Thanks for the replies brotha!
@@MaximumDIYGarage Btw, i found that my sponge filter was also completely missing. I also took the rest of the sais pump apart as well as the valves, and found no remnants of the filter. My theory is that the mice that were living in my valley took the sponge out for extra insulation.
Hi can the secondary fuel system be accessed without taking off the manifold.
Hi Richard! I’m sure you meant secondary air intake system, not fuel system. Unfortunately, no, you cannot access the pump or it’s components without removing the manifold because of its location.
Where is the egr valve located?
It is in the very back, by the fire wall
Nice vid. I'm working on my 2006 GX for this same situation. Had to take a break to look for vids on the subject. I seem to have a coolant leak somewhere from around the inlet valve and crossover pipe as well as from under the plenum. While a leaky inlet makes sense for a coolant leak, I'm confused as to why a plenum gasket would have any thing to do with this. There is no coolant flowing through there. How does replacing the intake gasket fix this?
Thank you! I was wondering the same thing! But replacing the plenum gasket has fixed the leak! Here’s an article: itstillruns.com/can-water-oil-blown-intake-gasket-12185060.html
@@MaximumDIYGarage I had the same question as Tim... Sounds like your leak came back according to your post on IH8MUD? Did you figure it out eventually?
I have seen some leaking this summer, but after just recently driving 200 miles I have not lost any coolant and there is no current leak. It is so weird. I only see the leak after the truck sits for a couple of weeks. Does that make any sense?
@@MaximumDIYGarage My situation turned out to be a failed water pump. Coolant was leaking from the timing belt cover in every direction including on to the top of the engine. So I got the whole timing belt and water pump job done. Was pricey but now I know for sure when the timing belt was last serviced and I had a highly rated shop do it with all OEM parts.
Thanks for sharing, Tim! How much did it cost you, if you don’t mind me asking?
I’m assuming $1,200-$1,600? It well worth it as these trucks are rock solid and it will pay you back with hundreds of thousands of miles and smiles!
great video thanks for sharing. why was there a coolant leak near the intake manifold? is there coolant running in the manifold?
@ iwantoffroad: thank you for watching! I was wondering the same thing myself when I researched the problem www.google.com/amp/s/www.autoblog.com/amp/2019/08/09/symptoms-of-bad-or-failing-intake-manifold-gaskets/
.
@iwantoffroad : great e30 content by the way!!!
iwantoffroad: here’s another article: itstillruns.com/can-water-oil-blown-intake-gasket-12185060.html
Can I use the UP-107 filter for LX470 vvti?
Yes sir! It’s the same engine and same setup
@@MaximumDIYGarage Thank you. Doing a knock sensor & Starter job on the 2UZFE vvti engine soon. I'll do this mod as well. Great video.
Thank you Kamal!
Would this save my SAIS from having to do a bypass and potentially spew more emissions? :O
Борис, если вы найдёте внутренний губчатый фильтр в целости, просто поменяйте его на внешний, как я показал в видео. К сожалению, если фильтра нет, как в моем случае, скорее всего он распался на мелкие кусочки и циркулирует внутри SAIS, и может забить один, или оба фильтра системы или сам мотор. Когда это случится не знает никто.
@@MaximumDIYGarage I see! Sorry I don't know much Russian so I had to use the google translator (I'm from Bulgaria) but thank you very much for the information!
I'll check on the sponge filter and decide from there then!
Also - incredible and detailed tutorial, very much appreciated!
@@Astor4o So sorry, Boris! I assumed you speak Russian based on your name.
If you find your sponge filter is intact, just replace it with the external one like I did. Unfortunately I didn’t not see mine, which can mean that the sponge filter has disintegrated and is now in pieces somewhere within SAIS and could potentially be stuck in one of the valves or both. No one knows
@@MaximumDIYGarage I see! Fingers crossed it doesn't cause any issues!
Again thank you for the incredible amount of effort you've put into this!
How do you say - Спасибо! :)
@@Astor4o I’m glad you found the video of my experience with it useful.
Fingers crossed everything goes well with your procedure of the SAIS filter. Good luck, sir!
I could not see in the video where the original (supposedly bad) filter was?
The original filter is a piece of foam. After 7-10 years ( depending on the climate and driving conditions) the foam dries out and disintegrates potentially sending dozens, if not hundreds, of small pieces into the SAIS. If one of those pieces gets stuck in one of the two, or both valves, the system will throw a code, the dash board lights up like a Christmas 🎄, and the truck goes into a limp mode. One of the two ways to fix the problem is to replace SAIS components ( pump, hoses, valves, etc), which can be as high as $800 (by indie mechanic) and $2000 by Lexus service dept; or do it by yourself if you feel confident and skilled doing the job (the cheapest option). You may need to do this again after 10 years or 130k miles or more. Or you can install an external breather filter instead and not worry about it. The other way to solve the problem is to buy and install a bypass kit ($200) which bypasses SAIS system and this problem is solved for good. The second option may make your truck ineligible to pass emissions test in some states and municipalities, so proceed the second option with caution.
In my case, I went there to replace the intake manifold gasket and just peeked inside the pump housing to see if the filter was there. It wasn’t…. So I took a gamble and installed an external filter and keep my fingers crossed the foam pieces are small enough to not block up the system components… If SAIS fails, at least I know how to get back in there! It’s been almost 2 years and everything is running smoothly! I hope this helps!
@@MaximumDIYGarage Just bought my 2nd 2006 GX470 (first one back on 06 and my ex sold it). Second one a couple of weeks ago with 155K miles on it. I changed the timing belt and water pump and a bunch of pulleys myself (big job) but didn't hear about this until today. It drives like a dream. I wonder if this is an issue on my car. I happen to just buy a snake camera and will try to poke inside if possible. Looks like the next gen placed this to the side of the engine (rather than under the manifold) and is MUCH easier to replace.
@Nicholas: yes sir! In your case, unless you are replacing the starter (not likely, most of 2UZ engines have over 300k miles on the original starter) or intake manifold gasket, I wouldn’t worry about it as many of fellow GX470 owners have driven over 200k+ miles without any issues with SAIS. On the other hand, if you are expecting to go to some very long trips or even expeditions (2,000, 4,000 or 6,000 mile trips) and want to be absolutely sure you will not get stuck in a limp mode somewhere in Alaska or South America, then the prudent thing to do would be to tear into it, and to make sure the original filter is still there. If it is, you’re in luck, which would be the best case scenario, replace it with an external breather-type filter, and you are set! If the filter is gone, you better replace the whole system, or install a bypass (see my previous comment for a warning). These are such fantastic trucks, it certainly is worth your time to keep yours in top running shape as they will not be making these with V8s much longer.
I agree that GX460 has a more serviceable SAIS system location, so does 4 Runner and Tacoma. However, the 1UR-FE engine in 460 is plagued with leaky timing chain cover seals, which are also a pita to replace. At least 1UR is a chain-driven engine, potentially saving you money on belt replacement (2UZ-FE) in a long run.
Join IH8MUD and ClubLexus forums for more info on your GX common issues.
Mine is an 09 and I intend to keep it for a while!
Enjoy yours!!!
@@MaximumDIYGarage Thanks for the feedback again! If the filter is gone, doesn't it mean it's already too late--damage done? Or are you saying that sometimes it gets sucked in and somehow manages to pass through the system without harming it (or setting any codes)?
Correct, Nicholas. My hope is that if the filter is gone, but the system is still functioning properly for several years and thousands of miles, you’re probably out of the woods. Now, there is no 100% guarantee that it won’t throw a code if a piece gets trapped somewhere, but very unlikely since it hasn’t happen yet.
Which year is this Lexus?
2009. This works for 2003-2009 Lexus GX470 and many other Toyota/Lexus models of that era.
@@MaximumDIYGarage Thanks