Remove and replace the intake manifold on a 2012-2017 Toyota Camry 2.5L I4 engine, including disconnection of fuel system, throttle body, and associated sensors.

Warnings

Tools required

Parts

• Intake manifold gasket × 1 — Use OEM specification
• Throttle body gasket × 1 — Use OEM specification
• PCV valve grommet × 1 — Use OEM specification
• Fuel injector O-rings (if disturbed) × 4 — Use OEM specification

Fluids

• Toyota Super Long Life Coolant (Pink) — 2 qt

Preparation

1. Park vehicle on level surface and ensure engine is completely cold (minimum 2 hours after last operation)
2. Disconnect negative battery terminal and wait 90 seconds for airbag system discharge
3. Remove engine cover by pulling upward on cover (friction fit)
4. Place drain pan under radiator and drain approximately 2 quarts of coolant from radiator petcock to below intake manifold level
5. Relieve fuel system pressure by removing fuel pump relay (EFI relay) and cranking engine until it stalls, then crank for 3 additional seconds
6. Label all vacuum hoses, electrical connectors, and fuel lines with tape or take reference photos

Procedure

1. 1

   Remove air intake system
   Disconnect the mass airflow sensor electrical connector. Loosen the air intake hose clamp at the throttle body. Remove the air filter housing bolts and lift the entire air intake assembly away from the engine bay. Disconnect any breather hoses attached to the air box.
2. 2

   Disconnect throttle body connections
   Disconnect the throttle position sensor electrical connector and the throttle body coolant bypass hoses (two small hoses). Use pliers to slide the spring clamps back and remove the coolant hoses. Have a shop towel ready to catch coolant spillage.
   ⚠Coolant will drain from bypass hoses. Keep drain pan positioned to catch spillage.
3. 3

   Remove throttle body
   Remove the four throttle body mounting bolts. Carefully pull the throttle body away from the intake manifold and set aside. Inspect the throttle body gasket and replace if damaged or reusing.
   Torque spec

   Throttle Body Bolts10 Nm (7 lb-ft)
4. 4

   Disconnect fuel system
   Using fuel line disconnect tools, disconnect the fuel feed line from the fuel rail. Press the disconnect tool into the quick-connect fitting while pulling the fuel line away. Cap the open fuel line with a plug or shop towel to prevent contamination and fuel spillage.
   ⚠️Even with pressure relieved, residual fuel will drain from fuel lines. Have shop towels and drain pan ready.
5. 5

   Disconnect fuel injector harness and remove fuel rail
   Disconnect the fuel injector wiring harness (single connector for all four injectors). Remove the two fuel rail mounting bolts. Carefully pull the fuel rail with injectors straight up and away from the intake manifold. Wiggle gently if resistance is felt. Set the fuel rail assembly aside in a clean area.
   Torque spec

   Fuel Rail Bolts12 Nm (9 lb-ft)
6. 6

   Disconnect vacuum lines and PCV system
   Disconnect the brake booster vacuum line from the intake manifold. Disconnect the EVAP purge line if equipped. Remove the PCV valve from the valve cover by twisting counterclockwise and pulling upward. Disconnect the PCV hose from the intake manifold.
   Torque spec

   PCV Valve8 Nm (6 lb-ft)
7. 7

   Disconnect remaining sensors and hoses
   Disconnect the intake manifold pressure sensor electrical connector. Disconnect any remaining vacuum hoses attached to the intake manifold, referring to your labels or photos. Remove the engine ground strap if it interferes with manifold removal.
8. 8

   Remove intake manifold support bracket
   Locate the intake manifold support bracket on the passenger side of the manifold. Remove the mounting bolts securing the bracket to both the intake manifold and the engine block. Remove the bracket.
   Torque spec

   Mounting Bolts47 Nm (35 lb-ft)
9. 9

   Remove intake manifold bolts
   Remove the six intake manifold mounting bolts/nuts in reverse sequence (working from outside toward center). Note that bolts may be different lengths - keep track of which bolt goes in which location. Carefully lift the intake manifold away from the cylinder head.
   ℹ️Manifold bolts should be removed in reverse of tightening sequence. Consult service manual for exact pattern.
   Torque spec

   Intake Manifold Bolts25 Nm (18 lb-ft)
10. 10

    Clean mating surfaces
    Thoroughly clean the intake manifold mating surface on the cylinder head using a plastic scraper. Remove all traces of old gasket material. Wipe clean with a lint-free cloth. Inspect for damage, warping, or cracks. Clean the intake manifold mating surface if reusing the manifold.
    ⚠Do not use metal scrapers on aluminum surfaces. Use only plastic scrapers to avoid gouging the sealing surface.
11. 11

    Install new intake manifold gasket
    Position the new intake manifold gasket onto the cylinder head. Ensure all port openings align correctly and gasket locating pins (if equipped) are properly seated. Do not use gasket sealant unless specified by manufacturer.
12. 12

    Install intake manifold
    Carefully lower the intake manifold onto the cylinder head, aligning all bolt holes. Start all six intake manifold bolts/nuts by hand to ensure proper threading. Tighten the bolts in sequence from center outward to 25.0 Nm (18 lb-ft) using a torque wrench. Verify tightening sequence with factory service manual.
    ⚠Follow proper tightening sequence to prevent manifold warping. Consult service manual for exact pattern before torquing.
    Torque spec

    Intake Manifold Bolts25 Nm (18 lb-ft)
13. 13

    Reinstall support bracket and reconnect sensors
    Reinstall the intake manifold support bracket and torque mounting bolts to specification. Reconnect the intake manifold pressure sensor electrical connector. Reconnect all vacuum hoses and the engine ground strap.
    Torque spec

    Mounting Bolts47 Nm (35 lb-ft)
14. 14

    Reinstall PCV system
    Install new PCV valve grommet into valve cover if needed. Install PCV valve into valve cover, turning clockwise until seated, and torque to 8.0 Nm (6 lb-ft). Connect PCV hose to intake manifold. Reconnect brake booster vacuum line and EVAP purge line.
    Torque spec

    PCV Valve8 Nm (6 lb-ft)
15. 15

    Reinstall fuel rail and injectors
    Inspect fuel injector O-rings and replace if worn or damaged. Lubricate new O-rings with clean engine oil. Carefully press the fuel rail with injectors straight down into the intake manifold until fully seated. Install the two fuel rail mounting bolts and torque in proper sequence to 12.0 Nm (9 lb-ft). Reconnect the fuel injector wiring harness. Reconnect the fuel feed line until the quick-connect fitting clicks into place.
    ℹ️Verify fuel rail bolt tightening sequence with service manual before torquing to ensure even injector seating.
    Torque spec

    Fuel Rail Bolts12 Nm (9 lb-ft)
16. 16

    Reinstall throttle body
    Install new throttle body gasket onto intake manifold. Position throttle body onto the manifold and install the four mounting bolts. Torque bolts in proper sequence to 10.0 Nm (7 lb-ft). Reconnect throttle body coolant bypass hoses and secure spring clamps. Reconnect throttle position sensor electrical connector.
    Torque spec

    Throttle Body Bolts10 Nm (7 lb-ft)
17. 17

    Reinstall air intake system
    Reinstall the air filter housing and air intake assembly. Tighten the air intake hose clamp at the throttle body. Reconnect all breather hoses. Reconnect the mass airflow sensor electrical connector.

Reassembly

1. Refill cooling system with Toyota Super Long Life Coolant (Pink) to proper level
2. Reconnect negative battery terminal
3. Reinstall engine cover
4. Turn ignition to ON position (do not start) for 2 seconds, then OFF. Repeat three times to prime fuel system
5. Check for fuel leaks around fuel rail and fuel line connections before starting engine

Verification

• Start engine and allow to reach operating temperature while monitoring for coolant leaks at throttle body bypass hoses
• Check for fuel leaks at fuel rail and injector seals during warm-up
• Check for vacuum leaks by listening for hissing sounds around intake manifold gasket and vacuum connections
• Verify smooth idle with no rough running or surging (may require throttle body relearn procedure via diagnostic tool or drive cycle)
• Test drive vehicle to confirm normal acceleration and no check engine light illumination
• Recheck coolant level after engine cools and top off if necessary

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