Toyota Celica, Corolla, ECHO & MR2 1999-05

Intake Manifold

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Removal & Installation



1NZ-FE Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Water filler
     
    Outer front cowl top panel
     
    Alternator
     
    Air cleaner
     
    Accelerator cable
     
    Ignition coil
     
    PCV hoses
     
    Throttle body
     
    Intake manifold and discard the gasket
     

  6.  

To install:

  1. Install or connect the following:

    Intake manifold with a new gasket. Uniformly tighten the bolts and nuts, in several passes, from the ends, working towards the center, to 22 ft. lbs. (30 Nm).
     
    Engine wiring harness
     
    Throttle body
     
    PCV hoses
     
    Ignition coils
     
    Accelerator cable
     
    Air cleaner
     
    Alternator
     
    Water filler
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

1ZZ-FE Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Drive belt and alternator
     
    Air intake duct
     
    Accelerator cable
     
    Exhaust pipe from the manifold.
     
    Exhaust manifold support bracket
     
    Spark plug wires, then ignition coils
     
    Spark plugs
     
    PCV hoses
     
    Throttle body assembly
     
    2 bolts securing the wiring harness protector
     
    Wiring connectors and ground wires
     
    Intake manifold support bracket
     
    Intake manifold and gasket

    Click image to see an enlarged view

    Fig. Intake manifold mounting fastener locations-1.8L (1ZZ-FE) engine

     

  6.  

To install:

  1. Install or connect the following:

    Intake manifold with a new gasket. Torque the bolts to 14 ft. lbs. (18.5 Nm).
     
    Harness wiring to the cylinder head and harness protector
     
    Fuel injectors, throttle body and the PCV hoses
     
    Spark plugs and ignition coils. Bolts and nuts: 80 inch lbs. (9 Nm).
     
    Exhaust manifold and support bracket. Bolts: 37 ft. lbs. (49 Nm).
     
    Front exhaust pipe to the manifold. Bolts: 46 ft. lbs. (62 Nm).
     
    Oxygen sensor. Nuts: 14 ft. lbs. (20 Nm).
     
    Accelerator cable and air intake duct
     
    Alternator and drive belt
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

2ZZ-GE Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Drive belt and alternator
     
    Air intake duct
     
    Accelerator cable
     
    Spark plug wires, then ignition coils
     
    Spark plugs
     
    PCV hoses
     
    Throttle body assembly
     
    Wiring harness
     
    Hoses and tubes connected to the head
     
    Intake manifold support bracket
     
    Intake manifold and gasket
     

  6.  

To install:

  1. Install or connect the following:

    Intake manifold with a new gasket. Bolts A: 20 ft. lbs. (27 Nm); bolt B: 34 ft. lbs. (46 Nm)
     
    Harness wiring to the cylinder head and harness protector
     
    Fuel injectors, throttle body and the PCV hoses
     
    Spark plugs and ignition coils. Bolts and nuts: 80 inch lbs. (9 Nm)
     
    Oxygen sensor. Nuts: 14 ft. lbs. (20 Nm).
     
    Accelerator cable and air intake duct
     
    Alternator and drive belt
     
    Negative battery cable
     



    Click image to see an enlarged view

    Fig. Intake manifold bolt installation-2ZZ-GE engine

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

5S-FE Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:
    NOTE
    On vehicles equipped with an air bag, wait at least 90 seconds before proceeding after disconnecting the negative battery cable.



    Negative battery cable.
     



    Accelerator cable. With automatic transmission, throttle cable from the throttle body
     
    Intake air temperature sensor connector
     
    On California models, air cleaner hose
     
    Air cleaner hose clamp bolt, air cleaner cap clips, air hose from the throttle body, and the air cleaner cap together with the resonator and air cleaner hose
     
    Electrical connections and hoses from the throttle body
     
    Throttle body. Type A throttle bodies are secured with 4 bolts and Type B throttle bodies are secured with 2 bolts and 2 nuts
     
    Vacuum hose bracket and the engine wiring harness
     
    EGR valve
     
    No. 1 air intake chamber, and manifold stays
     
    Intake manifold and gasket
     

  6.  

To install:

  1. Install or connect the following:
    NOTE
    The protrusion on the gasket should be facing down and the water hose connections on the throttle body should also face down.



    Intake manifold with a new gasket. Torque the bolts to 14 ft. lbs. (19 Nm)
     
    Wire clamps to the wire brackets on the intake manifold
     
    Vacuum hose bracket and engine wiring harness
     
    No. 1 air intake chamber and manifold stays. 14mm bolts: 31 ft. lbs. (42 Nm). 12mm bolts: 16 ft. lbs. (22 Nm)
     
    EGR valve
     
    Throttle body with a new gasket
     
    Hoses and electrical connections to the throttle body
     



    On type A throttle body, Bolts: 14 ft. lbs. (19 Nm). Bolt A is 45mm in length and bolt B is 55mm.

    Click image to see an enlarged view

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

     
    On type B throttle body, bolts and nuts: 14 ft. lbs. (19 Nm)
     
    PCV hose
     
    2 vacuum hoses to the EGR modulator
     
    Vacuum hose to the TVV for EVAP
     
    IAC valve connector
     
    Throttle position sensor connector
     
    Air cleaner hose to the throttle body
     
    Air cleaner cap with the resonator and air cleaner hose
     
    Intake air temperature sensor connector
     
    On California models, air hose to the air cleaner hose
     
    With automatic transmission, throttle cable
     
    Accelerator cable
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the vehicle, check for leaks and repair if necessary
  6.  

7A-FE Engine
  1. Disconnect the negative battery cable. On vehicles equipped with an air bag. Wait at least 90 seconds before proceeding.
  2.  


CAUTION
Work must NOT be started until after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative battery cable has been disconnected. The SRS is equipped with a back-up power source so that if work is started within 90 seconds of disconnecting the negative battery cable, the SRS may deploy. When the negative terminal cable is disconnected from the battery, memory of the clock and radio will be canceled. Before you start working, make a note of the contents memorized by the audio memory system. When you have finished working, reset the audio systems and adjust the clock. NEVER use a back-up power supply from outside the vehicle.


CAUTION
Fuel injection systems remain under pressure after the engine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Drain the engine coolant into a suitable container.
  2.  
  3. Disconnect the throttle body from the air intake chamber.
  4.  
  5. Disconnect the ground strap harness.
  6.  
  7. Tag and disconnect the hoses from the intake chamber.
  8.  



Click image to see an enlarged view

Fig. It is advisable to disconnect the hoses attached to the air intake chamber

  1. On vehicles with A/C remove the hose from the idle-up valve.
  2.  
  3. On vehicles with P/S remove the air hose from the air pipe.
  4.  



Click image to see an enlarged view

Fig. Disconnect the power steering hose from the air pipe

  1. Using a 6mm hexagon wrench, remove the three bolts, two nuts, and the air intake chamber cover and gasket.
  2.  



Click image to see an enlarged view

Fig. Remove the bolts and nuts retaining the air intake chamber



Click image to see an enlarged view

Fig. When lifting the lid, remove the gasket

  1. If equipped with EGR, remove the EGR VSV.
  2.  
  3. Remove the intake manifold stay.
  4.  
  5. Unbolt and remove the air pipe.
  6.  



Click image to see an enlarged view

Fig. Remember to label all hoses prior to removal



Click image to see an enlarged view

Fig. Unbolt the air pipe located under the intake manifold

  1. The engine wiring harness attached to the cylinder head may need to be disconnected to access bolts for the intake manifold.
  2.  
  3. Disconnect the fuel injector wiring.
  4.  
  5. Remove the union bolt and two gaskets and disconnect the fuel inlet hose from the delivery pipe. Place a shop towel under the connection to absorb the fuel.
  6.  
  7. Disconnect the fuel return hose from the fuel pressure regulator and the air hose from the IAC valve to the air pipe.
  8.  
  9. Remove the two bolts and the delivery pipe together with the four injectors.
  10.  
  11. Remove the seven bolts, four nuts, ground strap, intake manifold and the two gaskets.
  12.  



Click image to see an enlarged view

Fig. Remove the seven bolts and two nuts for the intake manifold ...



Click image to see an enlarged view

Fig. ... then lift the intake off the cylinder head



Click image to see an enlarged view

Fig. Be sure to remove the whole gasket, sometime parts get attached to the manifold or cylinder head

To install:

  1. Place a new intake manifold gasket to the cylinder head. Place a new EGR gasket to the cylinder head, with the protrusion facing down.
  2.  



Click image to see an enlarged view

Fig. Place the new intake manifold gasket on their mating areas correctly



Click image to see an enlarged view

Fig. Uniformly tighten the bolts and nuts in several passes on the intake manifold

  1. Install the intake manifold with seven bolts, four nuts, and the ground strap. Uniformly tighten the bolts and nuts in several passes. Tighten the A nuts to 9 ft. lbs. (13 Nm). Tighten all other nuts and bolts to 14 ft. lbs. (19 Nm).
  2.  
  3. Install the injectors and the delivery pipe.
  4.  
  5. If equipped with EGR, install the EGR VSV.
  6.  
  7. Install the air intake chamber cover with a new gasket.
  8.  
  9. Install the throttle body.
  10.  
  11. Install the air pipe and fuel inlet hose with the two bolts and nut. Install new gaskets on the fuel inlet hose and secure the clamp of the inlet hose to the intake manifold.
  12.  
  13. Connect the fuel return hose to the pressure regulator and the air hose from the IAC valve to the air pipe.
  14.  
  15. Install the intake manifold stay. Tighten the 12mm head bolt to 14 ft. lbs. (19 Nm) and the 14mm head bolt to 29 ft. lbs. (39 Nm).
  16.  
  17. Connect the hoses to the intake chamber.
  18.  
  19. If equipped, install the air hoses the idle-up valve and the air pipe.
  20.  
  21. Connect the ground strap connector and connect the fuel injector connectors.
  22.  
  23. Refill 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.
  24.  

 
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