Avalon 1995-1996

Intake Manifold

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Removal & Installation




CAUTION
The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel pressure from the fuel lines.
    1. Drain the engine coolant.
    2.  

  4.  
  5. With the ignition switch in the LOCK position, disconnect the negative battery terminal. If equipped with an air bag system, wait at least 90 seconds or longer before performing any other work.
  6.  
  7. Remove the air cleaner cap assembly and air filter.
  8.  
  9. Remove the V-bank cover.

    Click image to see an enlarged view

    Fig. Engine components, including intake manifold

  10.  
  11. Remove the air intake chamber assembly as follows:
    1. Disconnect the following connectors and cables:

      Accelerator cable
       
      Automatic transmission throttle cable
       
      Throttle Position Sensor (TPS) connector
       
      Idle Air Control (IAC) valve connector
       
      Exhaust Gas Recirculation (EGR) gas temperature sensor connector
       
      Vacuum Switching Valve (VSV) connector for the Acoustic Control Induction System (ACIS)
       
      VSV connector for the Evaporator Emissions (EVAP)
       
      VSV connector for the EGR
       
      Data Link Connector (DLC1) from the bracket on the intake air control valve
       

    2.  
    3. Remove the power steering pressure tube from the No. 1 engine hanger by removing the 2 bolts.
    4.  
    5. Disconnect the following hoses, clamps, and cables:

      Brake booster vacuum hose from the intake air control valve for the ACIS
       
      PCV hose from the PCV valve on the right-hand cylinder head
       
      Ground strap and cable from the air intake air control valve from the ACIS
       
      Ground cable from the air intake chamber
       
      Vacuum hose clamp from fuel pipe

      Click image to see an enlarged view

      Fig. Disconnect hoses, cables, and strap

       



      2 bypass hoses from the throttle body
       
      2 power steering air hoses from the air intake chamber
       
      Air assist hose from the throttle body
       
      EVAP hose from the pipe on emission control valve set
       
      2 vacuum hoses from the pipes on the cylinder head rear plate
       
      Vacuum sensing hose from the fuel pressure regulator
       
      Engine wire clamp from emission control valve set

      Click image to see an enlarged view

      Fig. Disconnect hoses and clamp

       

    6.  
    7. Remove the 2 bolts and the No. 1 engine hanger.
    8.  
    9. Remove the 2 bolts and the air intake chamber stay.
    10.  
    11. Remove the No. 2 EGR pipe and 2 gaskets by removing the 4 nuts.
    12.  
    13. Disconnect the hose from the VSV from the EVAP.
    14.  
    15. Using an 8mm hexagon wrench, remove the 2 bolts, 2 nuts, air intake chamber assembly and gasket.
    16.  

  12.  
  13. Disconnect the fuel injector connectors.
  14.  
  15. Remove the air assist hoses and pipe.
  16.  
  17. Disconnect the fuel return hose from the No. 1 fuel pipe.
  18.  
  19. Disconnect the fuel inlet hose from the fuel filter.
    NOTE
    Catch any fuel leaking from the filter in a shop rag. Dispose of the rag properly.

  20.  
  21. Remove the delivery pipes and injectors from the engine as follows:
    1. Loosen the 2 union bolts holding the No. 2 fuel pipe to the delivery pipes.
    2.  
    3. Disconnect the fuel return hose from the fuel pressure regulator.
    4.  
    5. Remove the union bolt and 2 gaskets for the right-hand delivery pipe.
    6.  
    7. Remove the 2 bolts to the left-hand delivery pipe, then remove the left-hand delivery pipe, 3 injectors, and the No. 2 fuel pipe as an assembly.
    8.  
    9. Remove the union bolt and 2 gaskets from the left-hand delivery pipe. Disconnect the No. 2 fuel pipe from the left-hand delivery pipe.
    10.  
    11. Remove the right-hand delivery pipe by removing the 3 bolts. Remove the delivery pipe, injectors, and the fuel inlet hose as an assembly.
    12.  
    13. Remove the 4 spacers from the intake manifold.
    14.  
    15. Pull out the 6 injectors from the delivery pipes.
    16.  
    17. Remove the 2 O-rings and 2 grommets from each injector.
    18.  

  22.  
  23. Remove the heater hoses from the intake manifold.
  24.  
  25. Remove the 9 bolts, 2 nuts, and 2 plate washers. Remove the intake manifold.

    Click image to see an enlarged view

    Fig. Intake manifold nut and bolt locations



    Click image to see an enlarged view

    Fig. View of the intake manifold prior to component removal



    Click image to see an enlarged view

    Fig. Remove the manifold gasket . . .



    Click image to see an enlarged view

    Fig. . . . then scrape all remaining materials from the mating surfaces

  26.  

To install:

  1. Thoroughly clean the intake manifold and cylinder head surfaces.
  2.  
  3. Using new gaskets, install the intake manifold with the 2 plate washers, 9 bolts, and 2 nuts. Tighten the nuts and bolts to 11 ft. lbs. (15 Nm).

    Click image to see an enlarged view

    Fig. Intake manifold nut and bolt tightening sequence

  4.  
  5. Install the heater hoses to the intake manifold.
  6.  
  7. Install the injectors as follows:
    1. Install 2 new grommets to each injector.
    2.  
    3. Apply a light coat of spindle oil or gasoline to the 2 O-rings and install them to each injector.
    4.  
    5. Install the injector into the delivery pipe by turning the injector back and forth. Install all the injectors into the delivery pipes. Be sure to position the injector electrical connector outward.
    6.  
    7. Place the 4 spacers in position on the intake manifold.
    8.  
    9. Place the right-hand delivery pipe and the No. 1 fuel pipe together with the 3 injectors in position on the intake manifold.
    10.  
    11. Temporarily install the 2 bolts holding the right-hand delivery pipe to the intake manifold.
    12.  
    13. Temporarily install the bolt holding the No. 1 fuel pipe to the intake manifold.
    14.  
    15. Place the left-hand delivery pipe and the No. 2 fuel pipe together with the 3 injectors in position.
    16.  
    17. Connect the fuel return hose to the fuel pressure regulator.
    18.  
    19. Temporarily install the 2 bolts holding the left-hand delivery pipe to the intake manifold.
    20.  
    21. Temporarily install the No. 2 fuel pipe to the left and right-hand delivery pipes with the union bolts and 2 new gaskets.
    22.  
    23. Check that the injectors rotate smoothly. If the injectors do not rotate smoothly, the probable cause is incorrect installation of the O-rings. Replace the O-rings.
    24.  
    25. Tighten the 4 bolts holding the delivery pipes to the intake manifold. Tighten the bolts to 84 inch lbs. (10 Nm).
    26.  
    27. Tighten the bolt holding the No. 1 fuel pipe to the intake manifold. Tighten the bolts to 14 ft. lbs. (20 Nm).
    28.  
    29. Tighten the 2 union bolts holding the No. 2 fuel pipe to the delivery pipes. Tighten the bolts to 24 ft. lbs. (33 Nm).
    30.  

  8.  
  9. Connect the fuel inlet hose to the fuel filter by installing the union bolt. Use 2 new gaskets when installing the union bolt. Tighten to 21 ft. lbs. (29 Nm).
  10.  
  11. Connect the fuel return hose to the No. 1 fuel pipe. When routing the fuel return hose, pass the hose under the heater hoses.
  12.  
  13. Connect the air assist hoses to the intake manifold, then install the air assist pipe to the bracket on the No. 1 fuel pipe.
  14.  
  15. Connect the injector connectors.
  16.  
  17. Install the air intake chamber assembly as follows:
    1. Using an 8mm hexagon wrench, install the air intake chamber with a new gasket. Install the 2 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes, then tighten the bolts and nuts to 32 ft. lbs. (43 Nm).
    2.  
    3. Connect the hose to the VSV for the EVAP system.
    4.  
    5. Install the 2 new gaskets and No. 2 EGR pipe with the 4 nuts. Tighten the nuts to 108 inch lbs. (12 Nm).
    6.  
    7. Install the No. 1 engine hanger with the 2 bolts. Tighten the bolts to 19 ft. lbs. (39 Nm).
    8.  
    9. Install the air intake chamber stay with the 2 bolts. Tighten the bolts to 14 ft. lbs. (20 Nm).
    10.  
    11. Connect the hoses, clamp, and cables as follows:

      Brake booster vacuum hose to the intake air control valve for the ACIS
       
      PCV hose to the PCV valve on the right-hand cylinder head
       
      Ground strap and cable to the intake air control valve for the ACIS
       
      Ground cable and strap with the nut. Tighten the nut to 10 ft. lbs. (15 Nm)
       
      Ground cable to air intake chamber
       
      Vacuum hose clamp to fuel pipe
       
      2 water bypass hoses to the throttle body
       
      Air assist hose to the throttle body
       
      2 power steering air hoses to the air intake chamber
       
      EVAP hose to the pipe on the emission control valve set
       
      2 vacuum hoses to the pipes on the cylinder head rear plate
       
      Vacuum sensing hose to the fuel pressure regulator
       
      Engine wire clamp to the emission control valve set
       

    12.  

  18.  
  19. Install the power steering pressure tube with the 2 nuts.
  20.  
  21. Connect the following connectors and cables:

    TPS sensor connector
     
    IAC valve connector
     
    EGR gas temperature sensor connector
     
    Air conditioning idle up valve connector
     
    VSV connector for the ACIS
     
    VSV connector for the fuel pressure control
     
    For California vehicles, install the VSV connector for the EVAP
     
    VSV connector for the EGR
     
    DLC1 to the bracket on the intake air control valve
     
    Accelerator cable
     
    Automatic transmission throttle cable
     

  22.  
  23. Install the V-bank cover.
  24.  
  25. Install the air cleaner hose to the engine.
  26.  
  27. Fill the engine coolant.
  28.  
  29. Connect the negative battery cable to the battery and start the engine.
  30.  
  31. Check the engine coolant level and check for leaks.
  32.  

 
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