Toyota Camry 1983-1996 Repair Guide

Intake Manifold

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REMOVAL & INSTALLATION




CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

1C-LTC and 2CL-TC Engines

See Figure 1

  1. Disconnect the negative battery cable.
  2.  
  3. Position a suitable drain pan under the radiator and drain the cooling system.
  4.  



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Fig. Fig. 1: View of the intake manifold

  1. Remove the turbocharger.
  2.  
  3. Remove the intake manifold with the fuel pipe by removing the six bolts and two nuts. Remove the intake manifold gasket.
  4.  

To install:
  1. Throughly clean the intake manifold and cylinder head surfaces with a soft brush and solvent.
  2.  
  3. Place the new gasket onto the intake manifold and attach the manifold to the cylinder head with six bolts and two nuts. Uniformly tighten the bolts and nuts in several passes to 13 ft. lbs. (18 Nm).
  4.  
  5. Install the turbocharger.
  6.  
  7. Fill the cooling system to the proper level. Change the engine oil and filter.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Start the engine and inspect for leaks.
  12.  
  13. Check and/or adjust the engine idle and maximum idle speeds.
  14.  

2S-ELC, 3S-FE and 5S-FE Engines

See Figure 2

  1. Disconnect the negative battery cable.
  2.  
  3. Position a suitable drain pan under the radiator drain cock and drain the cooling system.
  4.  



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Fig. Fig. 2: Intake manifold mounting

  1. Remove the accelerator cable return spring along with the cable and bracket from the throttle body.
  2.  
  3. Loosen the clamp and disconnect the air cleaner hose.
  4.  
  5. Disconnect the throttle position sensor harness. On 3S-FE engines, disconnect the Idle Speed Control (ISC) valve wiring also.
  6.  
  7. Disconnect, label and plug the following hoses:

    Two water by-pass hoses.
     
    PCV hoses from the throttle body.
     
    Inlet hose to the air valve.
     
    All emission vacuum hoses attached to the throttle body.
     
    Vacuum hose between the EGR valve and modulator.
     
    Power steering pump air hose (if equipped).
     

  8.  
  9. Loosen the union nut of the EGR pipe. Remove the two bolts, EGR valve modulator and gasket. Remove the bolt and the EGR valve.
  10.  
  11. Remove the bolts attaching the throttle body to the intake manifold. Remove the throttle body and gasket.
  12.  
  13. Remove the intake manifold stays and on the 5S-FE engine, the No. 1 air intake chamber.
  14.  
  15. Disconnect the vacuum sensing hose.
  16.  
  17. Remove the two nuts and seven bolts (1983-85 2S-ELC engines) or two nuts and six bolts (1986 2S-ELC and all 3S-FE and 5S-FE engines) that attach the intake manifold to the cylinder head.
  18.  
  19. On 5S-FE engines, remove the bolt, vacuum hose bracket and the main engine wire harness. On Calif. 5S-FE, remove the wire bracket.
  20.  
  21. Remove the intake manifold and gasket from the cylinder head.
  22.  

To install:
  1. Thoroughly clean the intake manifold and cylinder head surfaces. Using a machinist's straight edge and a feeler gauge, check the surface of the intake manifold for warpage. If the warpage is greater than 0.0118 inch (0.300mm), replace the intake manifold.
  2.  
  3. Place a new gasket onto the intake manifold and position the intake manifold onto the cylinder head with the proper amount of nuts and bolts. On 1983-85 2S-ELC engines tighten the nuts and bolts to 31 ft. lbs. (42 Nm). On all other engines, tighten the nuts and bolts to 14 ft. lbs. (19 Nm).
  4.  
  5. Install the intake manifold stays. Tighten the 12mm bolts to 14 ft. lbs. (19 Nm) and the 14mm bolts to 31 ft. lbs. (42 Nm).
  6.  
  7. Place a new gasket onto the throttle body and attach the unit to the intake manifold with the four bolts. Uniformly tighten the bolts in several passes to 14 ft. lbs. (19 Nm).
  8.  
  9. Install the EGR valve with new gasket and the modulator. Tighten the pipe union nut to 43 ft. lbs. (59 Nm) and the bolts to 9 ft. lbs. (13 Nm).
  10.  
  11. Unplug and connect all hoses.
  12.  
  13. Connect the throttle position sensor and ISC valve wiring.
  14.  
  15. Connect the air cleaner hose and tighten the hose clamp.
  16.  
  17. Attach the throttle cable with bracket onto the throttle body. Install the return spring.
  18.  
  19. On vehicles equipped with automatic transaxle, connect the accelerator cable and adjust it.
  20.  
  21. Fill the cooling system to the proper level and connect the negative battery cable.
  22.  
  23. Start the engine and inspect for leaks.
  24.  

2VZ-FE and 3VZ-FE Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Disconnect the throttle/accelerator cable from the throttle body.
  6.  
  7. Disconnect the air cleaner hose at the air intake chamber and remove it.
  8.  
  9. Remove the V-bank cover on the 3VZ-FE engine.
  10.  
  11. Tag and disconnect all lines and hoses and then remove both the ISC valve and the throttle body.
  12.  
  13. Remove the EGR valve and vacuum modulator. Remove the distributor.
  14.  
  15. On the 3VZ-FE, remove the emission control valve set and then disconnect the left side engine harness.
  16.  
  17. Remove the cylinder head rear plate.
  18.  
  19. Remove the intake chamber stays, any wires and remove the air intake chamber.
  20.  
  21. Remove the fuel injection delivery pipe and the injectors.
  22.  
  23. Remove the water outlet and the by-pass outlet.
  24.  
  25. Remove the two bolts and the No. 2 idler pulley bracket stay. Remove the eight bolts and four nuts and then lift out the intake manifold.
  26.  

To install:
  1. Thoroughly clean the intake manifold and cylinder head surfaces. Using a machinist's straight edge and a feeler gauge, check the surface of the intake manifold for warpage. If the warpage is greater than 0.0039 inch (0.10mm), replace the intake manifold.
  2.  
  3. Place new gaskets onto the intake manifold and position the intake manifold between the cylinder heads. Tighten the nuts and bolts to 13 ft. lbs. (18 Nm). Tighten the No. 2 pulley bracket bolts to 13 ft. lbs. (18 Nm).
  4.  
  5. Install the water by-pass outlet and tighten the bolts to 14 ft. lbs. (20 Nm) on the 2VZ-FE , or 74 inch lbs. (8 Nm) on the 3VZ-FE. Tighten the water outlet to 74 inch lbs. (8 Nm).
  6.  
  7. Install the injectors and delivery pipe.
  8.  
  9. Install the air intake chamber and tighten the two bolts and two nuts to 32 ft. lbs. (43 Nm). Install the chamber stays and tighten the mounting bolts to 27 ft. lbs. (37 Nm) on the 2VZ-FE, or 29 ft. lbs. (39 Nm) on the 3VZ-FE.
  10.  
  11. Install the distributor. Install the emission control valve set on the 3VZ-FE and tighten the two bolts to 73 inch lbs. (8 Nm).
  12.  
  13. Install the EGR valve and modulator (with new gaskets). Tighten the bolts and nuts to 13 ft. lbs. (18 Nm).
  14.  
  15. Place a new gasket onto the throttle body and attach the throttle body to the intake manifold with the four bolts. Tighten the bolts to 14 ft. lbs. (19 Nm).
  16.  
  17. Install the ISC valve and tighten it to 9 ft. lbs. (13 Nm).
  18.  
  19. Unplug and connect all hoses.
  20.  
  21. Connect the throttle position sensor and ISC valve wiring.
  22.  
  23. Connect the air cleaner hose and tighten the hose clamp.
  24.  
  25. Connect the throttle cable with bracket onto the throttle body. Install the return spring.
  26.  
  27. On vehicles equipped with automatic transaxle, connect the accelerator cable and adjust it.
  28.  
  29. Fill the cooling system to the proper level and connect the negative battery cable.
  30.  
  31. Start the engine and inspect for leaks.
  32.  

1MZ-FE Engine

See Figures 3, 4, 5, 6, 7, 8 and 9

  1. Remove the battery and battery tray.
  2.  
  3. Drain and recycle the engine coolant.
  4.  
  5. Disconnect the accelerator cable on automatic transaxles. Disconnect the throttle cable.
  6.  
  7. Remove the air cleaner cap assembly. Disconnect and label any wiring or hoses interfering with removal.
  8.  



Click image to see an enlarged view

Fig. Fig. 3: View of the intake manifold-1MZ-FE engine



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Fig. Fig. 4: View of the intake manifold prior to component removal

  1. Remove the right side engine mounting stay.
  2.  
  3. Disonnect the radiator and heater hoses in the way of the intake manifold removal.
  4.  
  5. Remove the V-bank cover.
  6.  
  7. Disconnect all the vacuum hose and wiring for the emission control valve set and remove.
  8.  
  9. Unbolt and remove the air intake chamber. Label all wiring and hoses. Discard the old gasket.
  10.  
  11. Remove the EGR pipe discard the old gaskets.
  12.  
  13. Unbolt and remove the hydraulic motor pressure hose from the air intake chamber.
  14.  
  15. Disconnect, unbolt and label the engine wiring harnesses from the left side, right side, rear and No. 3 timing belt cover.
  16.  



Click image to see an enlarged view

Fig. Fig. 5: Remove these bolts retaining the intake manifold-1MZ-FE engine

  1. Disconnect the front exhaust pipe and remove if necessary.
  2.  
  3. Remove the timing belt, camshaft timing pulleys, No. 2 idler pulley and No. 3 timing belt cover. Unbolt and remove the cylinder head rear plate.
  4.  
  5. Remove the two bolts, nuts and plate washers with the intake manifold. The delivery pipes with injectors will be attached to the manifold. Remove any other fuel related components such as the No. 2 fuel pipe and pulsation damper if needed.
  6.  
  7. Separate the delivery pipes from the intake manifold. Refer to Fuel System .
  8.  
  9. Clean and inspect the intake manifold mating surfaces. Scrape all old gasket martial off.
  10.  



Click image to see an enlarged view

Fig. Fig. 6: Remove the manifold gasket ...



Click image to see an enlarged view

Fig. Fig. 7: ... then scrape all remaining materials from the mating surfaces



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Fig. Fig. 8: Inspecting the warpage of the intake and exhaust manifolds

To install:
  1. Install the delivery pipes with injectors to the intake manifold. Make sure to place 4 spacers in position on the manifold. Temporarily install 4 bolts to retain the delivery pipes to the manifold. Inspect the injectors for smooth rotation. Refer to Fuel System . Once the injectors are seated properly, tighten the delivery pipes retaining bolts to 7 ft. lbs. (10 Nm).
  2.  



Click image to see an enlarged view

Fig. Fig. 9: Place the 4 spacers correctly into position on the intake manifold

  1. Install the No. 2 fuel pipe with union bolts and gaskets. Tighten the bolts to 24 ft. lbs. (32 Nm).
  2.  
  3. Install the No. 1 fuel pipe with pulsation damper, 4 new gaskets and the bolt, tighten the damper to 35 ft. lbs. (32 Nm) and the bolt to 11 ft. lbs. (15 Nm).
  4.  
  5. Install the fuel pressure regulator if removed, refer to Fuel System .
  6.  
  7. Attach the intake manifold and tighten the nine retaining bolts and two nuts in a crisscross pattern to 11 ft. lbs. (15 Nm). Make sure the gasket is in place properly prior to tightening.
  8.  
  9. Retighten the water outlet mounting bolts and nuts to 11 ft. lbs. (15 Nm) if loosened. Install the air assist hose and water inlet pipe. Place a new O-ring on the end of the water inlet pipe, apply a small amount of soapy water and tighten to 14 ft. lbs. (20 Nm).
  10.  
  11. Attach the ground strap. Attach any vacuum hoses removed to the air intake chamber and vacuum tank.
  12.  
  13. Install any remaining components, remember to use all new gaskets. Tighten the air intake chamber bolts and nuts to 32 ft. lbs. (43 Nm), the EGR pipe nuts to 9 ft. lbs. (12 Nm), the emission control valve set to 69 inch lbs. (8 Nm).
  14.  
  15. Install the air cleaner assembly. Connect the heater hoses. Install the battery and tray.
  16.  
  17. Connect the throttle cable with bracket onto the throttle body.
  18.  
  19. On vehicles equipped with automatic transaxle, connect the accelerator cable and adjust it.
  20.  
  21. Fill the cooling system to the proper level and connect the negative battery cable.
  22.  
  23. Start the engine and inspect for leaks.
  24.  

 
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