Intake Manifold: Service and Repair

Intake Manifold Replacement

Removal Procedure
Warning: Refer to Gasoline/Gasoline Vapors Warning Service Precautions.

Warning: Refer to Safety Goggles and Fuel Warning Safety Goggles and Fuel Warning.


Warning

In order to reduce the risk of fire and personal injury observe the following items:

* Replace all nylon fuel pipes that are nicked, scratched or damaged during installation, do not attempt to repair the sections of the nylon fuel pipes
* Do not hammer directly on the fuel harness body clips when installing new fuel pipes. Damage to the nylon pipes may result in a fuel leak.
* Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never expose the vehicle to temperatures higher than 115°C (239°F) for more than one hour, or more than 90°C (194°F) for any extended period.
* Apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe fittings. This will ensure proper reconnection and prevent a possible fuel leak. (During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.)

1. Open the hood.
2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (1.6L LDE, LXV, 1.8L 2H0, LUW and LFH) Air Cleaner Outlet Duct Replacement.
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.
4. Place a drain pan underneath the vehicle.




5. Remove the 2 intake manifold brace bolts (2, 3).
6. Remove and disconnect the wiring harness plug from the heated oxygen sensor 1.
7. Remove the intake manifold brace (1).
8. Remove the evaporative emission canister purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement Service and Repair




9. Unclip the fuel feed pipe (2) from the fuel feed pipe clip (3).
10. Release the fuel feed pipe (2) from the multiport fuel injection fuel rail (1) and remove the fuel feed pipe.
11. Close the fuel feed pipe with a suitable cap.




12. Remove the positive crankcase ventilation tube (1) from throttle body (3) and the camshaft cover (2).
13. Remove the throttle body assembly. Refer to Throttle Body Assembly Replacement (1.6L LDE, LXV, 1.8L 2H0, and LUW) Removal and Replacement.




14. Disconnect the manifold absolute pressure sensor wiring harness plug (5).
15. Remove the clamp (2) and remove the throttle body heater inlet hose (1) from throttle body (3).
16. Disconnect the throttle body heater outlet hose (4) from the throttle body (3).
17. Remove the engine management wiring harness and the fuel injectors wiring harness.




18. Remove the 2 multiport fuel injection fuel rail bolts (1).
19. Remove the multiport fuel injection fuel rail (2) and the fuel injectors (3) from the intake manifold (5).
20. Remove the 4 multiport fuel injector seals (4).




21. Disconnect the booster vacuum pipe (1) from the intake manifold.




22. Remove the 7 intake manifold bolts (1).
23. Remove the intake manifold (2).




24. Remove the intake manifold gaskets (1, 3) from the intake manifold (2).




25. Remove the manifold absolute pressure sensor bolt (1).
26. Remove the manifold absolute pressure sensor (2) from the intake manifold (3).




27. Remove the rubber bracket (2) from intake manifold (1).

Cleaning and Inspection Procedure

Clean and inspect the intake manifold. Refer to Intake Manifold Cleaning and Inspection (LDE, LED, LFJ, LXV, 2H0, LUW, LFH) 47. Intake Manifold Cleaning and Inspection.

Installation Procedure

1. Clean the sealing surfaces.




2. Install the rubber bracket (2) to intake manifold (1).




3. Install the manifold absolute pressure sensor (2) to the intake manifold (3).
4. Install the manifold absolute pressure sensor bolt (1) and tighten to 6 Nm (53 lb in).




5. Install the NEW gaskets (1, 3) to the intake manifold (2).





Caution: Refer to Fastener Caution Fastener Caution.

6. Install the intake manifold (2) and the 7 intake manifold bolts (1) and tighten to 20 Nm (15 lb ft).




7. Connect the booster vacuum pipe (1) to the intake manifold.




8. Install the 4 multiport fuel injector seals (4).
9. Install the multiport fuel injection fuel rail (2) and the fuel injectors (3) to the intake manifold (5).
10. Install the 2 multiport fuel injection fuel rail bolts (1) and tighten to 8 Nm (71 lb in).




11. Connect the throttle body heater outlet hose (4) to the throttle body (3).
12. Install the throttle body heater inlet hose (1) to the throttle body (3) and install the clamp (2).
13. Connect the manifold absolute pressure sensor wiring harness plug (5).
14. Install the engine management wiring harness and the fuel injectors wiring harness.




15. Install the positive crankcase ventilation tube (1) the to throttle body (3) and to the camshaft cover (2).
16. Install the throttle body assembly. Refer to Throttle Body Assembly Replacement (1.6L LDE, LXV, 1.8L 2H0, and LUW) Removal and Replacement.
17. Install the evaporative emission canister purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement Service and Repair




18. Remove the cap from fuel feed pipe (2).
19. Install the fuel feed pipe (2) to the multiport fuel injection fuel rail (1).
20. Clip the fuel feed pipe (2) to the fuel feed pipe clip (3).




21. Install the intake manifold brace (1).
22. Install and connect the wiring harness plug to the heated oxygen sensor 1.
23. Install the 2 intake manifold brace bolts (2, 3) and tighten to 8 Nm (71 lb in).
24. Lower the vehicle.
25. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (1.6L LDE, LXV, 1.8L 2H0, LUW and LFH) Air Cleaner Outlet Duct Replacement.
26. Close the hood.