Toyota Cressida and Van 1983-1990

Intake Manifold

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REMOVAL & INSTALLATION



5M-GE Engine


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Fig. Fig. 1 When installing the thermostat housing, do not tighten it too much, as it could easily break



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Fig. Fig. 2 Loosen and remove all of the intake manifold bolts-5M-GE engine

  1. Disconnect the negative battery cable. Drain the engine coolant. Relieve the fuel pressure from the fuel injection system.
  2.  
  3. Tag and disconnect all wires, hoses or cables that interfere with intake manifold removal.
  4.  
  5. Remove the air intake chamber.
  6.  
  7. Disconnect and move the wiring away from the fuel delivery and injector pipe.
  8.  
  9. Remove the fuel injector and delivery pipe.
  10.  
  11. Remove the fuel pressure regulator, which is mounted on the center of the intake manifold.
  12.  
  13. Remove the EGR valve from the rear of the manifold.
  14.  
  15. Disconnect the radiator hoses, heater hoses, and vacuum lines from the intake manifold.
  16.  
  17. Remove the distributor cap and position it out of the way.
  18.  
  19. Remove the intake manifold retaining bolts. Remove the intake manifold and gasket from the engine.
  20.  

To install:

  1. Install the intake manifold gasket along with the intake manifold. Install the intake manifold retaining bolts and torque to specification.
  2.  
  3. Install the distributor cap assembly.
  4.  
  5. Reconnect the radiator hoses, heater hoses, and vacuum lines going to the intake manifold.
  6.  
  7. Install the EGR valve to the rear of the manifold.
  8.  
  9. Install the fuel pressure regulator, which is mounted on the center of the intake manifold.
  10.  
  11. Install the fuel injector and delivery pipe.
  12.  
  13. Reconnect and put back in place the wiring to the fuel delivery and injector pipe.
  14.  
  15. Install the air intake chamber.
  16.  
  17. Reconnect all wires, hoses or cables that had interfered with the intake manifold removal.
  18.  
  19. Refill the coolant system. Reconnect the negative battery cable.
  20.  
  21. Start the engine check for any vacuum leaks at the intake manifold.
  22.  

7M-GE Engine


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Fig. Fig. 3 Intake manifold mounting-7M-GE engine

  1. Disconnect the negative battery cable. Drain the engine coolant. Relieve the fuel pressure from the fuel injection system.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Tag and disconnect all wires, hoses or cables that interfere with intake manifold removal.
  6.  
  7. Remove the necessary components in order to gain access to the intake manifold retaining bolts.
  8.  
  9. Remove the air intake connector along with the air intake chamber assembly.
  10.  
  11. Remove the fuel delivery pipe with the injectors still attached.
  12.  
  13. Remove the intake manifold retaining bolts. Remove the intake manifold from the vehicle.
  14.  

To install:

  1. Install the intake manifold gasket along with the intake manifold. Install the intake manifold retaining bolts and torque to specification.
  2.  
  3. Install the fuel delivery pipe along with the fuel injectors.
  4.  
  5. Install the air intake connector along with the air intake chamber assembly.
  6.  
  7. Install all the components that were removed in order to gain access to the intake manifold retaining bolts.
  8.  
  9. Reconnect and put back in place the wiring to the fuel delivery and injector pipe.
  10.  
  11. Reconnect all wires, hoses or cables that had interfered with the intake manifold removal.
  12.  
  13. Install the air cleaner assembly.
  14.  
  15. Reconnect all wires, hoses or cables that had interfered with the intake manifold removal.
  16.  
  17. Refill the coolant system. Reconnect the negative battery cable.
  18.  
  19. Start the engine check for any vacuum leaks at the intake manifold.
  20.  

3Y-EC and 4Y-EC Engines

Refer to the exhaust manifold procedure for intake manifold removal illustrations.

  1. Relieve the fuel pressure from the fuel injection system. Disconnect the negative battery cable and remove the right-hand seat and engine service hole cover.
  2.  
  3. Drain the engine coolant into a suitable container.
  4.  
  5. Remove the air cleaner to the throttle body hose.
  6.  
  7. Remove the accelerator cable with the bracket from the throttle body.
  8.  
  9. Disconnect the air valve, throttle position sensor and the oxygen sensor wiring.
  10.  
  11. Disconnect the PCV hose from the air intake chamber, the water bypass hoses from the throttle body, the booster vacuum hose and the charcoal canister hose, then label and disconnect the emission control cable.
  12.  
  13. Remove the throttle body from the air intake chamber, the EGR tube union nut from the exhaust manifold, the EGR valve from the air intake chamber.
  14.  
  15. Disconnect the cold start injector tube, water bypass hoses and the pressure regulator hose from the intake manifold.
  16.  
  17. Remove the air intake chamber brackets and the air intake chamber with the air valve from the intake manifold.
  18.  
  19. Remove the wire clamp bolt from the fuel injector rail, then, the fuel injector rail from the fuel injectors.
  20.  
  21. Remove the exhaust manifold to intake manifold bracket, the exhaust manifold to engine bracket, the exhaust pipe from the exhaust manifold, the fuel inlet and outlet tubes union nut from the fuel rail.
  22.  
  23. Remove the spark plug wires, the spark plugs and the tubes.
  24.  
  25. Remove the retaining nuts, then the intake manifold.
  26.  

To install:

  1. Clean the gasket mounting surfaces.
  2.  
  3. Installation is the reverse order of the removal procedure, except for the following.
  4.  
    1. Install new gaskets.
    2.  
    3. Tighten the manifold to cylinder head nuts to 36 ft. lbs. (49 Nm).
    4.  
    5. Tighten the air intake chamber to intake manifold bolts to 9 ft. lbs.
    6.  
    7. Tighten the throttle body bolts to 9 ft. lbs. (12 Nm).
    8.  
    9. Refill the cooling system. Start the engine and allow it to reach normal operating temperature and check for leaks. Repair as necessary.
    10.  


 
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