How to replace Intake Manifold on 2001 Toyota Camry?

Intake Manifold

Removal & Installation

1.8L Engine

1. Turn the ignition switch to the OFF , then disconnect the negative battery cable.
2. Remove the engine covers.
3. Drain the engine coolant into a sealable container.
4. Disconnect the hose for the Leak Detection Pump (LDP).
5. Disconnect the accelerator pedal cable from the throttle valve control module.
6. Remove the air guide hose from the throttle valve control module.
7. Disconnect the vacuum line from the Evaporative Emissions (EVAP) canister.
8. Detach the brake booster vacuum hose.
9. Disconnect the Intake Air Temperature (IAT) sensor and the throttle valve control module.
10. Detach the Camshaft Position (CMP) sensor wiring harness connector.
11. Properly relieve the fuel system pressure.
12. Disconnect the fuel rail with the injectors and position it aside in the engine compartment on a clean cloth.
13. Disconnect the coolant hoses attached to the intake manifold.
14. Disconnect the crankcase breather hose at the intake manifold.
15. Remove the intake manifold brace and the oil dipstick.
16. Unbolt the manifold at the mounting flange, then remove.
17. Stuff clean shop rags into the cylinder head ports to prevent debris from entering the engine.
18. Clean all gasket surfaces of any old gasket material.

To install:

1. Remove the rags from the cylinder head ports.
2. Install the intake manifold with new gaskets and tighten the mounting fasteners to 84 inch lbs. (10 Nm).
3. Connect the manifold brace and tighten the bracket mounting bolts to 15 ft. lbs. (20 Nm).
4. Install the dipstick.
5. Connect the crankcase breather and coolant hoses to the intake manifold.
6. Replace the fuel injector sealing O-rings, lubricate the O-rings with a light coating of fresh engine oil, then install the fuel rail with the injectors and tighten the retaining bolts to 88 inch lbs. (10 Nm).
7. Connect the CMP and the IAT sensors to the throttle valve control module.
8. Connect the brake booster and EVAP canister vacuum hoses.
9. Connect the air guide hose and the accelerator pedal cable to the throttle valve control module.
10. Connect the hose for the LDP.
11. Top off the engine coolant and bleed as necessary.
12. Reconnect the negative battery cable.
13. Fully close all power windows to stop, operate all window switches for at least 1 second in the close direction to activate the 1-touch opening/closing function.
14. Check the oil level before starting the engine, and top off as necessary.
15. Enter the radio security code.
16. Set the clock to the correct time.

NOTE

Diagnostic Trouble Codes (DTCs) may be stored when harness connectors are detached.

1. Read the DTCs and clear the fault codes.

Fig. To remove the crimped vacuum hose clamp, first insert a suitable pick tool into the crimped opening, then . . .

Fig. . . . move the pick from side . . .

Fig. . . . to side while pressing inward on the pick. If necessary insert a small flat blade screwdriver and repeat the process until the clamp is sufficiently loose. Once removed, replace the clamp

1. Before servicing the vehicle, refer to the precautions section.
2. Drain the engine coolant.
3. Properly relieve the fuel system pressure.
4. Turn the ignition switch to the OFF .
5. Remove or disconnect the following:
   
   
   Negative battery cable

   Engine covers

   Hose for the Leak Detection Pump (LDP)

   Accelerator pedal cable from the throttle valve control module

   Air guide hose from the throttle valve control module

   Vacuum line from the Evaporative Emissions (EVAP) canister

   Brake booster vacuum hose

   Intake Air Temperature (IAT) sensor and the throttle valve control module

   Camshaft Position (CMP) sensor wiring harness connector

   Fuel rail with the injectors

   Coolant hoses from to the intake manifold

   Crankcase breather hose at the intake manifold

   Intake manifold brace and the oil dipstick

   Manifold at the mounting flange
   
   
6. Clean all gasket surfaces.

To install:

1. Install or connect the following:
   
   
   Intake manifold using new gaskets. Torque the fasteners to 89 inch lbs. (10 Nm).

   Manifold brace. Torque the bolts to 15 ft. lbs. (20 Nm).

   Dipstick

   Crankcase breather and coolant hoses to the intake manifold

   Fuel injector sealing O-ring

   Fuel rail with the injectors. Torque the bolts to 89 inch lbs. (10 Nm).

   CMP and the IAT sensors to the throttle valve control module

   Brake booster and EVAP canister vacuum hoses

   Air guide hose and the accelerator pedal cable to the throttle valve control module

   Hose for the LDP
   
   
2. Top off the engine coolant and bleed, if necessary.
3. Connect the negative battery cable.
4. Fully close all power windows to stop, operate all window switches for at least 1 second in the close direction to activate the one-touch opening/closing function.
5. Check the oil level before starting the engine and top off, as necessary.

2.7L Engines

1. Before servicing the vehicle, refer to the precautions section.
2. Drain the engine coolant.
3. Properly relieve the fuel system pressure.
4. Turn the ignition switch to the OFF .
5. Remove or disconnect the following:
   
   
   Negative battery cable

   Wastegate bypass regulator from fuel rail

   Connector from EVAP canister purge valve

   Connector at turbocharger recirculating valve

   Recirculating valve hose clamps

   Fuel pressure regulator hose clamps

   Exhaust temperature sensors, (leave connected)

   Brake booster hose

   Vacuum reservoir hose

   Connectors for fuel injectors

   Suction hose at turbocharger

   Hose clamps at bypass valve, turbocharger intake line and fuel vapor line

   Fuel rail (4) bolts

   Throttle valve connector

   Air pressure sensor connector

   Pressure hoses at front of engine

   Bypass valve hose

   Intake air temperature sensor connector

   PCV hose

   Fuel return and supply lines to fuel rail

   EVAP valve hose
   
   
6. Remove fuel rail and injectors and support fuel rail
7. Remove intake manifold
   
   
   

   

   Fig. Component view of the intake manifold assembly and related components-2.7L engine

To install:

1. Installation is the reverse of the removal procedure, using the following torque values:
   
   
   Fuel rail bolts: 84 inch lbs. (10 Nm)

   Intake manifold bolts: 84 inch lbs. (10 Nm)
   
   

2.8L Engine

1. Before servicing the vehicle, refer to the precautions section.
2. Disconnect the negative battery cable.
3. Properly relieve the fuel system pressure.
4. Remove or disconnect the following:
   
   
   Fuel supply and return lines

   Fuel injector electrical connectors and the retainers for the fuel injectors

   Fuel pressure regulator clamp and the regulator

   Fuel manifold

   Injectors

   Any hoses or connectors associated with the intake manifold

   Upper intake manifold mounting bolts

   Upper intake manifold and discard the gasket

   Idle Air Control (IAC) valve

   Exhaust Gas Recirculation (EGR) valve

   Accelerator cable form the throttle body

   Lower intake manifold mounting bolts

   Lower intake manifold
   
   
5. Clean all gasket mating surfaces.

To install:

Fig. Exploded view of the fuel injector assembly-2.8L engine

Fig. Exploded view of the upper/lower intake manifold assembly and related components-2.8L engine

1. Install or connect the following:
   
   
   Lower intake manifold using a new gasket. Torque the bolts to 15 ft. lbs. (20 Nm).

   EGR valve

   Accelerator cable to the throttle body

   IAC valve. Torque the bolts to 89 inch lbs. (10 Nm).

   Upper intake manifold. Torque the short bolts to 89 inch lbs. (10 Nm) and the long bolts to 15 ft. lbs. (20 Nm).

   All hoses or connectors that were removed

   Fuel injectors using new O-rings

   Fuel manifold. Torque the bolts to 89 inch lbs. (10 Nm).

   Pressure regulator and clamp

   Fuel injector retainers

   Electrical connectors

   Fuel return and supply lines

   Negative battery cable
   
   

2.8L V6 Engine

1. Disconnect the negative battery cable.
2. Properly relieve the fuel system pressure.
3. Disconnect the fuel supply and return lines.
4. Detach the fuel injector electrical connectors and the retainers for the fuel injectors.
5. Remove the fuel pressure regulator clamp, then the regulator.
6. Unbolt and remove the fuel manifold, then the injectors.
7. Label and detach any hoses or connectors associated with the intake manifold.
8. Remove the upper intake manifold mounting bolts, then the manifold and gasket.
9. Remove the Idle Air Control (IAC) valve.
10. Disconnect the EGR valve.
11. Disconnect the accelerator cable form the throttle body.
12. Remove the lower intake manifold mounting bolts, then the manifold.
13. Clean all gasket mating surfaces of old gasket material.
14. Place shop rag in the cylinder head openings to prevent dirt and debris from entering the open port.

Fig. Exploded view of the fuel injector assembly-2.8L V6 Engine

Fig. Exploded view of the upper/lower intake manifold assembly and related components-2.8L V6 Engine

To install:

1. Remove the shop rags from the cylinder head openings.
2. Install the lower intake manifold using a new gasket, and tighten the mounting bolts to 15 ft. lbs. (20 Nm).
3. Connect the EGR valve.
4. Attach the accelerator cable to the throttle body.
5. Install the IAC valve and tighten the mounting bolts to 84 inch lbs. (10 Nm).
6. Install the upper intake manifold and tighten the short mounting bolts to 84 inch lbs. (10 Nm) and the long mounting bolts to 15 ft. lbs. (20 Nm).
7. Attach any hoses or connectors that were removed.
8. Install the fuel injectors using new O-rings, lubricate the O-rings with a light coating of fresh engine oil, then install the fuel manifold and tighten the mounting bolts to 88 inch lbs. (10 Nm).
9. Install the pressure regulator and clamp.
10. Install the fuel injector retainers, and then attach the electrical connectors.
11. Attach the fuel return and supply lines.
12. Connect the negative battery cable.
13. Check and clear any stored fault codes.

3.0L Engine

1. Before servicing the vehicle, refer to the precautions section.
2. Drain the engine coolant.
3. Properly relieve the fuel system pressure.
4. Turn the ignition switch to the OFF .
5. Remove or disconnect the following:
   
   
   Negative battery cable

   Engine covers

   Air filter induction tube

   EVAP canister purge valve at air filter housing

   Connector at Mass Air Flow (MAF) sensor

   Air guide hose with MAF sensor

   Air filter housing

   Vacuum hoses at intake manifold change-over valve and check valve

   PCV hose

   Solenoid valve holding plate

   Fuel injector connectors

   Fuel pressure regulator

   Fuel distributor with fuel injectors

   All remaining vacuum and electrical connectors

   Remaining air ducting from throttle body

   Dipstick tube

   Secondary air injection system

   Coolant hoses

   Intake manifold
   
   

To install:

1. Installation is the reverse of the removal procedure, using the following torque values:
   
   
   Fuel rail bolts: 84 inch lbs. (10 Nm)

   Intake manifold bolts: 84 inch lbs. (10 Nm)

   All remaining bolts, except M8 on AIR: 84 inch lbs. (10 Nm)

   M8 bolts on AIR system: 17 ft. lbs. (23 Nm)
   
   

3.2L Engine

1. Before servicing the vehicle, refer to the precautions section.
2. Drain the engine coolant.
3. Properly relieve the fuel system pressure.
4. Turn the ignition switch to the OFF .
5. Remove or disconnect the following:
   
   NOTE

   Before removing ribbed belt, mark direction of rotation with chalk or a felt pen. If a used belt rotates in the wrong direction when reinstalled, this can result in breakage. When installing belt, ensure it is correctly seated in the pulleys.
   
   
   
   NOTE

   The air conditioning compressor can only be removed from the bracket with the upper securing bolt still inserted. To accomplish this, press the engine simultaneously to the left side. If necessary, loosen all bolts of the assembly mounting.
   
   
   
   
   Negative battery cable

   Right and left covers at lock carrier, above main fuse box and coolant expansion tank
   
   
   
   
   Release tension on belt by screwing an M8 x 40 bolt into bore on tensioning element and remove belt

   Upper mounting bolt for the alternator

   Upper mounting bolts for radiator cowl

   Secondary air hose

   Center and right-hand noise insulation under engine

   Cross piece

   Power steering pump from bracket, hang pump from lock carrier with hoses still attached

   Secondary air injection pump with bracket

   Lower radiator cowl bolts and remove the radiator cowl with fans
   
   
   
   
   Mounting bolt for air conditioning compressor

   Secure the air conditioning compressor together with the hoses at front longitudinal member (hoses remain connected)

   Alternator

   Oil dipstick tube

   Vacuum reservoir

   Mounting bracket for alternator and air conditioning compressor

   Bolts at front of intake manifold

   Attach puller T10095A or equivalent to ignition coils and remove coils

   Body brace

   Air intake hose

   Crankcase breather hose

   Throttle body

   Hose bracket

   Rear intake mounting bolts, swing intake manifold forward

   Fuel rail with fuel injectors

   Swing back to installed position and remove manifold
   
   

To install:

1. Installation is the reverse of the removal procedure, using the following torque values:
   
   
   Intake manifold to cylinder head 115 inch lbs. (13 Nm)

   Bracket for water pump to cylinder block 15 ft. lbs. (20 Nm)

   Intake manifold support to intake manifold 15 ft. lbs. (20 Nm)

   Throttle body to intake manifold 88 inch lbs. (10 Nm)
   
   

4.2L Engine

1. Before servicing the vehicle, refer to the precautions section.
2. Relieve the fuel system pressure.
3. Remove or disconnect the following:
   
   
   Negative battery cable

   Noise insulation panel

   Intake air grille in bumper

   Accessory drive belt

   Timing belt

   Vacuum line to brake booster unit

   Vacuum line at cruise control module

   Accelerator pedal cable

   Coolant lines to heater core (supply and return to vent valves)

   Left and right knock sensor connectors at fuel rail and remove cable ties (4x)

   Fuel injector harness connectors

   Fuel rail, carefully remove along with fuel injectors, and place down to one side

   Intake manifold
   
   

To install:

1. Install or connect the following:
   
   
   Intake manifold. Tighten the fasteners to 15 ft. lbs. (20 Nm).

   Fuel rail. Tighten the bolts to 84 inch lbs. (10 Nm).

   Fuel injector harness connectors

   Left and right knock sensor connectors at fuel rail

   Coolant lines to heater core (supply and return to vent valves)

   Accelerator pedal cable

   Vacuum line at cruise control module

   Vacuum line to brake booster unit

   Timing belt

   Accessory drive belt

   Intake air grille in bumper

   Noise insulation panel

   Negative battery cable
   
   

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