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Inlet Manifold Replacement — 1.6L LDE and LXV

Removal Procedure
  1. Open the bonnet.
  2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement : 1.6L LDE, LXV, 1.8L 2H0, and LUW .
  3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  4. Drain the cooling system. Refer to Cooling System Draining and Filling .

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  5. Remove the 2 inlet manifold brace bolts (2, 3).
  6. Remove and disconnect the wiring harness plug of the heated oxygen sensor 1.
  7. Remove the inlet manifold brace (1).
  8. Lower the vehicle by its full height.

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  9. Disconnect wiring harness plug.
  10. Disconnect the pipes from the evaporative emission canister purge solenoid valve (1).
  11. Remove the evaporative emission canister purge solenoid valve (1) and the rubber mounting from the inlet manifold (2).
  12. Remove the positive crankcase ventilation tube. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement : 1.6L LDE, LXV, 1.8L 2H0, and LUW .
  13. Remove the throttle body assembly. Refer to Throttle Body Assembly Replacement : 1.6L LDE, LXV, 1.8L 2H0, and LUW .
  14. Disconnect the manifold absolute pressure sensor wiring harness plug. Refer to Manifold Absolute Pressure Sensor Replacement : 1.8L 2H0 and LUW → 1.6L LDE and LXV .
  15. Remove the engine management wiring harness and the fuel injectors wiring harness.

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  16. Remove the 2 evaporative emission canister purge solenoid valve bracket bolts (2).
  17. Remove the evaporative emission canister purge solenoid valve bracket (1) from the inlet manifold (7).
  18. Remove the 2 multiport fuel injection fuel rail bolts (3).
  19. Remove the multiport fuel injection fuel rail (4) and the fuel injectors (5) from the inlet manifold (7).
  20. Remove the 4 multiport fuel injector seals (6).
  21. Remove the manifold absolute pressure sensor. Refer to Manifold Absolute Pressure Sensor Replacement : 1.8L 2H0 and LUW → 1.6L LDE and LXV .

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  22. Disconnect the booster vacuum pipe (1) from the inlet manifold.

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

Cleaning and Inspection Procedure

Clean and Inspect the inlet manifold. Refer to Inlet Manifold Cleaning and Inspection : LDE, LED, LFJ, LXV, 2H0, LUW .

Installation Procedure
  1. Clean the sealing surfaces.
  2. Install the NEW gasket.

    3. Caution: Refer to Fastener Caution in the Preface section.


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  3. Install the inlet manifold (2) and the 7 inlet manifold bolts (1) and tighten to 20 N·m (15 lb ft).

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  4. Connect the booster vacuum pipe (1) to the inlet manifold.
  5. Install the manifold absolute pressure sensor. Refer to Manifold Absolute Pressure Sensor Replacement : 1.8L 2H0 and LUW → 1.6L LDE and LXV .

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  6. Install the 4 multiport fuel injector seals (6).
  7. Install the multiport fuel injection fuel rail (4) and the fuel injectors (5) to the inlet manifold (7).
  8. Install the 2 multiport fuel injection fuel rail bolts and tighten to 8 N·m (71 lb in).
  9. Install the evaporative emission canister purge solenoid valve bracket (1) to the inlet manifold (7).
  10. Install the 2 evaporative emission canister purge solenoid valve bracket bolts (2) and tighten to 8 N·m (71 lb in).
  11. Install the engine management wiring harness.
  12. Connect the manifold absolute pressure sensor wiring harness plug. Refer to Manifold Absolute Pressure Sensor Replacement : 1.8L 2H0 and LUW → 1.6L LDE and LXV .
  13. Install the throttle body assembly. Refer to Throttle Body Assembly Replacement : 1.6L LDE, LXV, 1.8L 2H0, and LUW .
  14. Install the positive crankcase ventilation tube. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement : 1.6L LDE, LXV, 1.8L 2H0, and LUW .

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  15. Install the evaporative emission canister purge solenoid valve (1) and the rubber mounting to the inlet manifold (2).
  16. Connect the pipes to the evaporative emission canister purge solenoid valve (1).
  17. Connect the wiring harness plug.
  18. Raise the vehicle.

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  19. Install the inlet manifold brace (1).
  20. Install and disconnect the wiring harness plug of the heated oxygen sensor 1.
  21. Install the 2 intake manifold brace bolts (2; 3) and tighten to 8 N·m (71 lb in)
  22. Lower the vehicle.
  23. Fill the cooling system. Refer to Cooling System Draining and Filling .
  24. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement : 1.6L LDE, LXV, 1.8L 2H0, and LUW .
  25. Close the bonnet.
   


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