Toyota Camry and Avalon 1997-2000

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.

5S-FE Engines


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Fig. Intake manifold and related components-5S-FE engine



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Fig. Location of ground strap bolts-5S-FE engine



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Fig. Location of the intake manifold bolts-5S-FE engine

  1. Disconnect the negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding.
  2.  
  3. Drain the engine coolant into a suitable container.
  4.  
  5. Disconnect the accelerator cable from the throttle body. If equipped with automatic transmission, disconnect the throttle cable from the throttle body.
  6.  
  7. Disconnect the intake air temperature sensor connector
  8.  
  9. On California models, disconnect the air cleaner hose.
  10.  
  11. Loosen the air cleaner hose clamp bolt, disconnect the 4 air cleaner cap clips, disconnect the air hose from the throttle body, and remove the air cleaner cap together with the resonator and the air cleaner hose.
  12.  
  13. Tag and remove the electrical connections and hoses from the throttle body.
  14.  
  15. Remove the throttle body. Type A throttle bodies are secured with 4 bolts and Type B throttle bodies are secured with 2 bolts and 2 nuts.
  16.  
  17. Remove the vacuum hose bracket and the engine wiring harness from the intake manifold.
  18.  
  19. Remove the Exhaust Gas Recirculation (EGR) valve.
  20.  
  21. Remove the 4 bolts, the wire bracket, the No. 1 air intake chamber, and the manifold stays. Remove the 6 bolts, 2 nuts, the intake manifold, and the gasket.
  22.  

To install:

  1. Install the intake manifold to the cylinder head with a new gasket. Tighten the 6 bolts and the 2 nuts in several passes to 14 ft. lbs. (19 Nm). Install the 2 wire clamps to the wire brackets on the intake manifold.
  2.  
  3. Install the vacuum hose bracket and the engine wiring harness.
  4.  
  5. Install the No. 1 air intake chamber and manifold stays with the 4 bolts. Tighten the 14mm bolts to 31 ft. lbs. (42 Nm) and tighten the 12mm bolts to 16 ft. lbs. (22 Nm).
  6.  
  7. Install the EGR valve.
  8.  
  9. Install the throttle body with a new gasket on the intake chamber. Connect the hoses and electrical connections to the throttle body.
  10.  


NOTE
The protrusion on the gasket should be facing down and the water hose connections on the throttle body should also face down.

  1. On type A throttle body, tighten the 4 bolts to 14 ft. lbs. (19 Nm). Bolt A is 45mm in length and bolt B is 55mm
  2.  



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Fig. Mounting bolt length identification for the throttle body-2.2L (5S-FE) engine

  1. On type B throttle body, tighten the 2 bolts and the 2 nuts to 14 ft. lbs. (19 Nm).
  2.  
  3. Make the following connections to the throttle body:
  4.  
  5. The PCV hose
  6.  
  7. The 2 vacuum hoses from the Exhaust Gas Recirculation (EGR) modulator
  8.  
  9. The vacuum hose from the TVV for Evaporator Emissions (EVAP)
  10.  
  11. The Idle Air Control (IAC) valve connector
  12.  
  13. The throttle position sensor connector
  14.  
  15. Connect the air cleaner hose to the throttle body and install the air cleaner cap together with the resonator and the air cleaner hose. Connect the intake air temperature sensor connector.
  16.  
  17. On California models, connect the air hose to the air cleaner hose.
  18.  
  19. If equipped with automatic transmission, connect and adjust the throttle cable. Connect the accelerator cable.
  20.  
  21. Fill the cooling system with coolant and connect the negative battery cable. Start the engine, check for leaks, and road test the vehicle for proper operation.
  22.  

1MZ-FE Engine


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Fig. Upper intake manifold and its components



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



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Fig. View of the intake manifold prior to component removal



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



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Fig. Remove the manifold gasket . . .



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



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Fig. Inspecting the warpage of the intake and exhaust manifolds



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


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. Relieve the fuel pressure from the fuel lines.
  2.  
  3. 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.
  4.  
  5. Remove the air cleaner hose from the engine compartment.
  6.  
  7. Remove the V-bank cover from the engine.
  8.  
  9. Remove the air cleaner chamber assembly as follows:
  10.  
    1. Drain the engine coolant from the vehicle.
    2.  
    3. Disconnect the following connectors and cables:
    4.  
    5. Accelerator cable
    6.  
    7. automatic transmission throttle cable
    8.  
    9. Throttle Position Sensor (TPS) connector
    10.  
    11. Idle Air Control (IAC) valve connector
    12.  
    13. Exhaust Gas Recirculation (EGR) gas temperature sensor connector
    14.  
    15. air conditioning idle up valve connector
    16.  
    17. Vacuum Switching Valve (VSV) connector for the Acoustic Control Induction System (ACIS)
    18.  
    19. VSV connector for the fuel pressure control
    20.  
    21. Disconnect the VSV for the Evaporator Emissions (EVAP)
    22.  
    23. VSV connector for the EGR
    24.  
    25. Data Link Connector (DLC1) from the bracket on the intake air control valve
    26.  
    27. Remove the power steering pressure tube from the No. 1 engine hanger by removing the 2 bolts.
    28.  
    29. Disconnect the following hoses, clamps, and cables:
    30.  
    31. Brake booster vacuum hose from the intake air control valve for the ACIS
    32.  
    33. PCV hose from the PCV valve on the right-hand cylinder head
    34.  
    35. Ground strap and cable from the air intake air control valve from the ACIS
    36.  
    37. Ground cable from the air intake chamber
    38.  
    39. Vacuum hose clamp from fuel pipe
    40.  
    41. 2 bypass hoses from the throttle body
    42.  
    43. 2 power steering air hoses to the air intake chamber.
    44.  
    45. Air assist hose from the throttle body
    46.  
    47. Remove the EVAP hose from the pipe on emission control valve set
    48.  
    49. 2 vacuum hoses from the pipes on the cylinder head rear plate
    50.  
    51. Vacuum sensing hose from the fuel pressure regulator
    52.  
    53. Engine wire clamp from emission control valve set
    54.  
    55. Remove the 2 bolts and the No. 1 engine hanger.
    56.  
    57. Remove the 2 bolts and the air intake chamber stay.
    58.  
    59. Remove the No. 2 EGR pipe and 2 gaskets by removing the 4 nuts.
    60.  
    61. Disconnect the hose from the VSV from the EVAP.
    62.  
    63. Using an 8mm hexagon wrench, remove the 2 bolts. Remove the 2 nuts, the air intake chamber assembly and gasket.
    64.  

  11. Disconnect the fuel injector connectors.
  12.  
  13. Remove the air assist hoses and pipe.
  14.  
  15. Disconnect the fuel return hose from the No. 1 fuel pipe.
  16.  
  17. Disconnect the fuel inlet hose from the fuel filter.
  18.  


NOTE
Catch any fuel leaking from the filter in a shop rag. Dispose of the rag properly.

  1. Remove the delivery pipes and injectors from the engine as follows:
  2.  
    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.  

  3. Remove the heater hoses from the intake manifold.
  4.  
  5. Remove the 9 bolts, 2 nuts, and 2 plate washers. Remove the intake manifold.
  6.  

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).
  4.  
  5. Install the heater hoses to the intake manifold.
  6.  
  7. Install the injectors as follows:
  8.  
    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.  

  9. Connect the fuel inlet hose to the fuel filter by installing the union bolt. Use 2 new gaskets when installing the union bolt.
  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:
  18.  
    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:
    12.  
    13. Brake booster vacuum hose to the intake air control valve for the ACIS.
    14.  
    15. PCV hose to the PCV valve on the right-hand cylinder head.
    16.  
    17. Ground strap and cable to the intake air control valve for the ACIS.
    18.  
    19. Connect the ground cable and strap with the nut. Tighten the nut to 10 ft. lbs. (15 Nm)
    20.  
    21. Ground cable to air intake chamber
    22.  
    23. Vacuum hose clamp to fuel pipe.
    24.  
    25. 2 water bypass hoses to the throttle body.
    26.  
    27. Air assist hose to the throttle body.
    28.  
    29. 2 power steering air hoses to the air intake chamber.
    30.  
    31. Connect the EVAP hose to the pipe on the emission control valve set
    32.  
    33. 2 vacuum hoses to the pipes on the cylinder head rear plate.
    34.  
    35. Vacuum sensing hose to the fuel pressure regulator.
    36.  
    37. Engine wire clamp to the emission control valve set.
    38.  

  19. Install the power steering pressure tube with the 2 nuts.
  20.  
  21. Connect the following connectors and cables:
  22.  
  23. TPS sensor connector
  24.  
  25. IAC valve connector
  26.  
  27. EGR gas temperature sensor connector
  28.  
  29. air conditioning idle up valve connector
  30.  
  31. VSV connector for the ACIS
  32.  
  33. VSV connector for the fuel pressure control
  34.  
  35. For California vehicles, install the VSV connector for the EVAP
  36.  
  37. VSV connector for the EGR
  38.  
  39. DLC1 to the bracket on the intake air control valve
  40.  
  41. Accelerator cable
  42.  
  43. Automatic transmission throttle cable
  44.  
  45. Install the V-bank cover.
  46.  
  47. Install the air cleaner hose to the engine.
  48.  
  49. Fill the engine coolant.
  50.  
  51. Connect the negative battery cable to the battery and start the engine.
  52.  
  53. Check the engine coolant level and check for leaks.
  54.  

 
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