This procedure covers removal and installation of the intake manifold on the 2018-2024 Toyota Camry 2.5L I4 engine, including disconnection of all related sensors, hoses, and electrical connections.

Warnings

Tools required

Parts

• Intake manifold gasket × 1 — Use OEM specification
• Throttle body gasket × 1 — Use OEM specification
• PCV valve grommet (if damaged) × 1 — Use OEM specification
• Intake manifold mounting bolts (if damaged or corroded) × 6 — Use OEM specification

Fluids

• Toyota Super Long Life Coolant (Pink) — 1 qt

Preparation

1. Ensure engine is completely cool to the touch (wait at least 2 hours after last engine operation)
2. Park vehicle on level surface, engage parking brake, and chock rear wheels
3. Disconnect negative battery terminal and wait 90 seconds
4. Remove engine cover by pulling upward on front edge, then lifting away
5. Place drain pan under engine and partially drain coolant from radiator drain valve until level is below intake manifold
6. Take detailed photos of all vacuum lines, electrical connectors, and hose routing
7. Organize workspace with parts containers and label all fasteners by location

Procedure

1. 1

   Remove air intake system
   Loosen clamp on air intake tube at throttle body. Disconnect mass airflow sensor electrical connector. Remove air filter housing bolts and lift entire air intake assembly away from engine bay. Remove intake duct from throttle body.
2. 2

   Disconnect throttle body electrical connector
   Press release tab and disconnect throttle body electrical connector. Move wiring harness aside and secure away from work area. Do not pull on wires, only on connector body.
3. 3

   Remove throttle body
   Remove four throttle body mounting bolts. Carefully separate throttle body from intake manifold. Remove and discard throttle body gasket. Cover throttle body opening with clean shop towel to prevent debris entry.
   ℹ️Inspect throttle body bore for carbon buildup. Clean if necessary before reinstallation.
   Torque spec

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

   Disconnect vacuum lines and hoses
   Disconnect brake booster vacuum line from intake manifold. Disconnect PCV hose from valve cover. Disconnect EVAP purge line from intake manifold. Disconnect any remaining vacuum lines, noting their positions. Disconnect coolant bypass hoses from intake manifold (two hoses on passenger side).
   ⚠Coolant will drain from bypass hoses. Have drain pan ready and plug hoses with rubber caps to minimize coolant loss.
5. 5

   Disconnect fuel system components
   Disconnect fuel injector electrical connectors (four connectors). Remove fuel rail bolts following service manual sequence if specified. Carefully pull fuel rail with injectors straight up and away from intake manifold. Secure fuel rail assembly aside without disconnecting fuel lines. Cover injector ports in intake manifold with clean shop towels.
   ⚠Do not bend or stress fuel injector wiring. Keep fuel rail upright to prevent fuel leakage.
   Torque spec

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

   Disconnect remaining sensors and components
   Disconnect intake manifold pressure sensor electrical connector. Disconnect any remaining sensor connectors attached to intake manifold. Remove wiring harness brackets and clips securing harness to intake manifold. Move all wiring clear of intake manifold removal path.
   Torque spec

   Mounting Bolts47 Nm (35 lb-ft)

   Electrical Connector Bolts7 Nm (5 lb-ft)
7. 7

   Remove PCV valve
   Twist and pull PCV valve from valve cover grommet. Inspect grommet for damage or deterioration. If grommet is damaged, remove and replace. Note orientation of PCV valve for reinstallation.
   ℹ️PCV valve may be tight in grommet. Use twisting motion while pulling to avoid tearing grommet.
   Torque spec

   PCV Valve8 Nm (6 lb-ft)
8. 8

   Remove intake manifold mounting bolts
   Remove intake manifold support bracket bolts if present. Loosen and remove all intake manifold mounting bolts in reverse of tightening sequence (working from outside toward center). There are typically six bolts securing the intake manifold. Keep bolts organized by location.
   Torque spec

   Intake Manifold Bolts25 Nm (18 lb-ft)

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

   Remove intake manifold
   Carefully lift intake manifold straight up and away from cylinder head. If manifold is stuck, gently tap with soft mallet or use plastic pry tool at casting bosses only. Never pry against gasket surfaces. Once free, remove manifold from engine bay. Remove and discard intake manifold gasket.
   ⚠Intake manifold is aluminum and relatively lightweight but awkward to handle. Support entire assembly to prevent dropping.
10. 10

    Clean gasket surfaces
    Use plastic gasket scraper to carefully remove all old gasket material from cylinder head and intake manifold mating surfaces. Do not use metal scrapers that could gouge aluminum surfaces. Clean surfaces with brake cleaner and lint-free shop towels. Inspect both surfaces for cracks, warping, or damage. Vacuum or blow out intake ports in cylinder head to remove any debris. Cover intake ports with clean shop towels until ready to install new manifold.
    ⚠️Do not allow any debris, gasket material, or tools to fall into open intake ports. Foreign objects will cause catastrophic engine damage.
    ⚠Gasket surfaces must be completely clean and dry for proper seal. Any oil, coolant, or debris will cause vacuum leaks.
    Torque spec

    Gasket Surface Bolts20 Nm (15 lb-ft)
11. 11

    Install new gasket and intake manifold
    Remove shop towels from intake ports. Position new intake manifold gasket on cylinder head, ensuring all bolt holes and port openings align correctly. Carefully lower intake manifold onto gasket, ensuring gasket does not shift out of position. Start all intake manifold bolts by hand to ensure proper thread engagement. Tighten bolts in sequence from center outward to specified torque in two stages: first to 12 Nm, then final torque to 25 Nm.
    ⚠Follow service manual tightening sequence exactly. Improper sequence can warp intake manifold and cause vacuum leaks.
    ℹ️Use torque wrench for final tightening. Over-torque will strip aluminum threads.
    Torque spec

    Intake Manifold Bolts25 Nm (18 lb-ft)
12. 12

    Install PCV valve and reconnect hoses
    Install PCV valve into valve cover grommet using twisting motion. Ensure valve is fully seated. Reconnect PCV hose to intake manifold. Reconnect brake booster vacuum line. Reconnect EVAP purge line. Reconnect all remaining vacuum lines to their original positions per reference photos. Reconnect coolant bypass hoses and secure with clamps.
    Torque spec

    PCV Valve8 Nm (6 lb-ft)
13. 13

    Install fuel rail and injectors
    Remove shop towels from injector ports. Lubricate fuel injector O-rings with clean engine oil. Carefully align fuel rail and injectors with intake manifold ports. Press fuel rail straight down until all injectors are fully seated. Install fuel rail bolts and tighten following service manual sequence to specified torque. Reconnect all fuel injector electrical connectors.
    ⚠Ensure injectors seat squarely in ports. Cocked or misaligned injectors will leak and cause poor running condition.
    Torque spec

    Fuel Rail Bolts12 Nm (9 lb-ft)
14. 14

    Install throttle body
    Install new throttle body gasket on intake manifold. Position throttle body on gasket and install mounting bolts. Tighten bolts in cross pattern to specified torque. Reconnect throttle body electrical connector until it clicks into place.
    Torque spec

    Throttle Body Bolts10 Nm (7 lb-ft)
15. 15

    Reconnect sensors and install air intake
    Reconnect intake manifold pressure sensor and all remaining sensor electrical connectors. Reinstall wiring harness brackets and secure harness with clips. Install air intake system in reverse order of removal. Tighten air intake tube clamp at throttle body. Reconnect mass airflow sensor electrical connector. Install engine cover.
    Torque spec

    Mounting Bolts47 Nm (35 lb-ft)

    Electrical Connector Bolts7 Nm (5 lb-ft)

Reassembly

1. Refill cooling system with Toyota Super Long Life Coolant (Pink) to proper level
2. Reconnect negative battery terminal
3. Verify all electrical connectors are fully seated and locked
4. Check that all vacuum lines and hoses are properly connected and secured
5. Verify no tools or shop towels were left in engine bay

Verification

• Start engine and allow to idle. Listen for vacuum leaks (hissing sound) around intake manifold and throttle body
• Check for fuel leaks around fuel rail and injectors while engine is running
• Check for coolant leaks at bypass hoses on intake manifold
• Verify idle is smooth and stable with no rough running or misfires
• Allow engine to reach operating temperature and verify coolant level is stable with no loss
• Scan for diagnostic trouble codes. There should be no codes related to intake air, fuel system, or sensor circuits
• Perform test drive and verify smooth acceleration with no hesitation or loss of power
• Recheck all bolts after first heat cycle (50-100 miles) to ensure they remain properly torqued

More procedures for this vehicle