In order to replace the Intake Manifold, the following components have to be removed:
Throttle Body; oil fill tube;
Fuel Injectors. Depress the clutch pedal and use a 24-mm socket to remove the crankshaft bolt. Disconnect the
Knock Sensor harness connector and take the electrical harness aside. If modified, unscrew the egr pipe bolts from the Intake Manifold , cylinder head and the
Exhaust Manifold and then remove the egr pipe (with valve) and egr pipe gasket from the Exhaust Manifold. Firstly remove the positive crankcase ventilation (PCV) hose (with valve),
MAP Sensor , accelerator control cable bracket bolts , and the bracket itself. Separate the evaporative emission (EVAP) purge solenoid vent tube by separating the evap section of tube from the solenoid, as well as squeezing the evap pipe quick connect fitting retainer, and the evap section of tube from the vapor pipe. Take out the evap purge solenoid bolt , isolator , and the Intake Manifold bolts , before removing the Intake Manifold and its gaskets , and dump the old gaskets. If equipped, clean the gasket surfaces of the egr pipe and Exhaust Manifold. In installation, new Intake Manifold gaskets should go on the Intake Manifold, then the manifold goes on. Apply a threadlock gm p/n 12345382 (Canadian P/N 10953489) or equivalent, for (5 mm) 0.20 inch band, on the threads of the Intake Manifold bolts. Tighten Intake Manifold bolts in a sequence of 5 nm (44 inch lbs.) for first pass and 10 nm (89 inch lbs.) for the final pass. Mount the evap purge solenoid, isolator and bolt onto the Intake Manifold and tighten the bolt of the solenoid to 10 nm (89 referred to as inch lbs.). Mount the evap purge solenoid vent tube to the solenoid and vapor pipe, and then install the accelerator control cable bracket and its bolts, tightening to 10 nm (89 inch lbs.). Gently apply clean engine oil on the seal of the MAP Sensor and install it onto the Intake Manifold, including the hose of the pcv with valve. If installed, replace the new egr pipe gasket on the Exhaust Manifold and egr pipe (with valve), bolts onto Intake Manifold, cylinder head, and Exhaust Manifold until snug. Lastly, fasten the
EGR Valve pipe-to-manifold interface bolts to 10nm (89inch lbs.), the EGR Valve pipe-to-cylinder head bolts to 50nm (37ft lbs.) and finally the EGR Valve pipe-to-exhaust manifold bolts to 30nm (22ft lbs.). Run the electrical harness into position, install the Knock Sensor harness on the Intake Manifold & reattach the MAP Sensor, knock sensor & egr valve if so equipped. Complete by installing the fuel injectors, oil fill tube, and Throttle Body.