Camry 2008-2009

Intake Manifold

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Removal & Installation



2.4L Engine
Hybrid

CAUTION
Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly, take safety precautions, such as wearing insulated gloves and removing the service plug grip to prevent electrical shocks. Make sure to turn the power switch off before removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain and recycle the engine coolant.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the or disconnect the following:


    1. Two nuts and the engine cover.
    2.  
    3. Air cleaner inlet assembly.
    4.  
    5. Mass air flow meter connector.
    6.  
    7. Purge VSV connector.
    8.  
    9. Purge line hose from the clamp.
    10.  
    11. No. 2 ventilation hose from the air cleaner hose.
    12.  
    13. Lock the No. 1 air cleaner hose clamp, and then disconnect the No. 1 air cleaner hose from the throttle body.
    14.  
    15. Two bolts and air cleaner cap.
    16.  
    17. Throttle position sensor connector and wire harness clamp.
    18.  
    19. Four bolts, and then remove the fuel pipe support and throttle body.
    20.  
    21. Purge line hose from the throttle body.
    22.  
    23. Water by-pass hose from the throttle body.
    24.  
    25. N o. 2 water by-pass hose from the throttle body.
    26.  
    27. No. 1 throttle body hose from the throttle body.
    28.  
    29. Gasket from the intake manifold.

      Click image to see an enlarged view

      Fig. Removing intake manifold bolts

    30.  
    31. Five bolts, two nuts, and intake manifold
    32.  
    33. Gasket from the intake manifold.
    34.  

  8.  

To install:

  1. To install, reverse removal procedure.
  2.  
  3. Install a new throttle body gasket onto the intake manifold.
  4.  
  5. Tighten the throttle body bolts and fuel pipe clamp to: 22 ft. lbs. (30 Nm).
  6.  
  7. Install a new intake manifold gasket.
  8.  
  9. Tighten the intake manifold bolts and nuts to: 22 ft. lbs. (30 Nm).
  10.  
  11. Add coolant and check for leaks.
  12.  

2.4L Hybrid Engine

Specific to:

Toyota Camry 2009-2010

  1. Disconnect the fuel system pressure.
  2.  
  3. Disconnect the cable from the negative battery terminal.
  4.  
  5. Remove the No. 1 engine cover sub assembly.
  6.  
  7. Drain the engine coolant.
  8.  
  9. Remove the windshield wiper arm and blade assemblies.
  10.  
  11. Remove the front fender to cowl side seals.
  12.  
  13. Remove the cowl top ventilator louver sub assembly.
  14.  
  15. Separate the brake master cylinder reservoir sub assembly.
  16.  
  17. Remove the windshield wiper motor and link.
  18.  
  19. Remove the cowl top panel outer sub assembly.
    1. Remove the 4 bolts, 4 nuts and the cowl top panel outer sub assembly.
    2.  

  20.  
  21. Remove the air cleaner cap sub assembly.
  22.  
  23. Remove the air cleaner case sub assembly.
  24.  
  25. Remove the throttle body.
  26.  
  27. Disconnect the fuel tube.
  28.  
  29. Remove the fuel delivery pipe with the injector.
  30.  
  31. Remove the intake manifold.
    1. Disconnect the union to check valve hose from the brake booster.
    2.  
    3. Disconnect the camshaft timing oil control valve connector.
    4.  
    5. Remove the wire harness clamp.
    6.  
    7. Remove the union to check valve hose from the vacuum hose clamp.
    8.  
    9. Remove the 5 bolts, 2 nuts and the intake manifold.

      Click image to see an enlarged view

      Fig. Removing and installing the intake manifold

    10.  

  32.  

To install:

  1. Install the intake manifold.
    1. Install a new gasket into the intake manifold.
    2.  
    3. Install the intake manifold with the 5 bolts and 2 nuts. Tighten to 22 ft. lbs. (30 Nm).
    4.  
    5. Fit the union to check valve hose into the vacuum hose clamp.
    6.  
    7. Install the wire harness clamp.
    8.  
    9. Connect the camshaft timing oil control valve connector.
    10.  
    11. Connect the union to check valve hose to the brake booster.
    12.  

  2.  
  3. Install the fuel delivery pipe with the injector.
  4.  
  5. Install the fuel tube.
  6.  
  7. Install the throttle body.
  8.  
  9. Install the air cleaner case sub assembly.
  10.  
  11. Install the air cleaner cap sub assembly.
  12.  
  13. Install the air cleaner inlet assembly.
  14.  
  15. Connect the cable to the negative battery terminal.
  16.  
  17. Add engine coolant.
  18.  
  19. Inspect for coolant leaks.
  20.  
  21. Inspect for fuel leaks.
  22.  
  23. Install the No. 1 engine cover sub assembly.
  24.  
  25. Install the cowl top panel outer sub assembly. Tighten the bolts to 44 inch lbs. (5 Nm). Tighten the nuts to 63 ft. lbs. (85 Nm).
  26.  
  27. Install the brake master cylinder reservoir sub assembly.
  28.  
  29. Install the windshield wiper motor and link.
  30.  
  31. Install the cowl top ventilator louver sub assembly.
  32.  
  33. Install the front fender to cowl side seals.
  34.  
  35. Install the windshield wiper arm and blade assemblies.
  36.  
  37. Perform initialization.
  38.  

3.5L Engine

Specific to:

Toyota Camry 2007-2008

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the engine assembly with transaxle.
  4.  
  5. Secure the engine.
  6.  
  7. Remove the ignition coil assembly.
  8.  
  9. Remove the right No. 2 engine mounting stay.
  10.  
  11. Remove the intake manifold, as follows:
    1. Uniformly loosen and remove the 6 bolts and 4 nuts.

      Click image to see an enlarged view

      Fig. Locating intake manifold bolts and nuts

    2.  
    3. Remove the intake manifold and 2 gaskets.
    4.  

  12.  

To install:

  1. Install the intake manifold, as follows:
    WARNING
    DO NOT apply oil to the intake manifold and cylinder head sub-assembly bolts.

    1. Set a new gasket on each cylinder head.
      NOTE
      Align the port holes of the gasket and cylinder head.


      NOTE
      Make sure that the gasket is installed in the correct direction.

    2.  
    3. Set the intake manifold on the cylinder heads.
    4.  
    5. Install and tighten the 6 bolts and 4 nuts uniformly in several steps to 15 ft. lbs. (21 Nm).
    6.  

  2.  
  3. Install the right No. 2 engine mounting stay.
  4.  
  5. Install the ignition coil assembly.
  6.  
  7. Install the engine assembly with transaxle.
  8.  

Specific to:

Toyota Camry 2009-2010

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the engine assembly with transaxle.
  4.  
  5. Secure the engine.
  6.  
  7. Remove the ignition coil assembly.
  8.  
  9. Remove the right No. 2 engine mounting stay.
  10.  
  11. Remove the intake manifold, as follows:
    1. Uniformly loosen and remove the 6 bolts and 4 nuts.

      Click image to see an enlarged view

      Fig. Locating intake manifold bolts and nuts

    2.  
    3. Remove the intake manifold and 2 gaskets.
    4.  

  12.  

To install:

  1. Install the intake manifold, as follows:
    WARNING
    DO NOT applies oil to the intake manifold and cylinder head sub-assembly bolts.

    1. Set a new gasket on each cylinder head.
      NOTE
      Align the port holes of the gasket and cylinder head.


      NOTE
      Make sure that the gasket is installed in the correct direction.

    2.  
    3. Set the intake manifold on the cylinder heads.
    4.  
    5. Install and tighten the 6 bolts and 4 nuts uniformly in several steps to 15 ft. lbs. (21 Nm).
    6.  

  2.  
  3. Install the right No. 2 engine mounting stay.
  4.  
  5. Install the ignition coil assembly.
  6.  
  7. Install the engine assembly with transaxle.
  8.  

 
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