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Inlet Manifold Replacement

Removal Procedure
  1. Remove the exhaust gas recirculation valve cooler. Refer to Exhaust Gas Recirculation Valve Cooler Replacement .
  2. Remove the 2 inlet air tuning valve vacuum control solenoid valves. Refer to Inlet Air Tuning Valve Vacuum Control Solenoid Valve Replacement .

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  3. Remove the charge air control vacuum hose bracket bolt (1) from inlet manifold.
  4. Remove the 2 charge air control vacuum hose bracket bolts (2) from engine front cover.

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  5. Remove the 4 throttle body assembly bolts (3).
  6. Remove the throttle body assembly (2) along with the gasket (1).
  7. Remove the starter. Refer to Starter Replacement : 2.0L Diesel LNP with MT → 2.0L Diesel LNP with AT → 1.4L LDD, LUH, and LUJ → 1.6L LDE, LXV, 1.8L 2H0, and LUW → 1.6L LXT,L2W → 2.0L Diesel LLW .

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  8. Remove the vacuum regulator valve hose (1) from charge air bypass valve vacuum tank (4).
  9. Remove the vacuum pump hose (2) from the charge air bypass valve vacuum tank (4).
  10. Remove the 2 charge air bypass valve vacuum tank bracket bolts (3).

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  11. Remove the inlet manifold bracket bolt (5).
  12. Remove the 4 lower inlet manifold bolts (6).
  13. Lower the vehicle.
  14. Remove the 2 intake manifold nuts (3).
  15. Remove the 2 upper inlet manifold bolts (4).
  16. Remove the intake manifold (2).
  17. Remove the inlet manifold gasket (1).

Installation Procedure

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  1. Install the inlet manifold (2) along with a NEW inlet manifold gasket (1).

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

  2. Install the 2 upper inlet manifold bolts (4) and the 2 inlet manifold nuts (3) and tighten to 25 N·m (18 lb ft).
  3. Raise the vehicle.
  4. Install 4 lower inlet manifold bolts (6) and tighten to 25 N·m (18 lb ft).
  5. Install inlet manifold bracket bolt (5) and tighten to 25 N·m (18 lb ft).

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  6. Install 2 charge air bypass valve vacuum tank bracket bolts (3) and tighten to 10 N·m (89 lb in).
  7. Install the vacuum pump hose (2) to the charge air bypass valve vacuum tank (4).
  8. Install the vacuum regulator valve hose (1) to the charge air bypass valve vacuum tank (4).
  9. Install the starter. Refer to Starter Replacement : 2.0L Diesel LNP with MT → 2.0L Diesel LNP with AT → 1.4L LDD, LUH, and LUJ → 1.6L LDE, LXV, 1.8L 2H0, and LUW → 1.6L LXT,L2W → 2.0L Diesel LLW .
  10. Lower the vehicle.

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  11. Install the throttle body assembly (2) along with a NEW gasket (1).
  12. Install 4 throttle body assembly bolts (3) and tighten to 10 N·m (89 lb in).

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  13. Install the 3 charge air control vacuum hose bolts (1, 2) and tighten to 9 N·m (80 lb ft).
  14. Install the 2 inlet air tuning valve vacuum control solenoid valves. Refer to Inlet Air Tuning Valve Vacuum Control Solenoid Valve Replacement .
  15. Install the exhaust gas recirculation valve cooler. Refer to Exhaust Gas Recirculation Valve Cooler Replacement .
   


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