Orlando

Inlet Manifold Replacement

Special Tools

For equivalent regional tools, refer to Special Tools .

Warning: Petrol or petrol vapours are highly flammable. A fire could occur if an ignition source is present. Never drain or store petrol or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

Warning: Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash.

1. Open the bonnet.
2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System .
3. Remove the dash upper extension panel opening cover. Refer to Dash Upper Extension Panel Opening Cover Replacement .
4. Place a drip pan underneath.
5. Relieve the fuel pressure, using the test connection with EN-34730-91 gauge .
6. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
7. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .



8. Disconnect the oxygen wiring harness (3).
9. Remove the wiring harness bracket (1) from the inlet manifold (2).



10. Remove the 2 intake manifold brace bolts (2, 3).
11. Remove the intake manifold brace (1).
12. Lower the vehicle.



13. Remove the fuel tank vent pipe (1) from the evaporative emission canister purge solenoid valve (3). Refer to Plastic Collar Quick Connect Fitting Service .
14. Close the fuel tank vent pipe (1) with EN-6015 closure plugs .



15. Disconnect wiring harness plug (3).
16. Disconnect the pipe (5) from the evaporative emission canister purge solenoid valve (2) to intake manifold (4). Refer to Plastic Collar Quick Connect Fitting Service .
17. Remove the 2 evaporative emission canister bracket bolts (1).
18. Remove the evaporative emission canister purge solenoid valve (2) and the rubber mounting from the intake manifold (4).
19. Close the fuel tank vent pipe with EN-6015 closure plugs .



20. Unclip the fuel feed pipe (1) from the fuel feed pipe clip (2). Refer to Plastic Collar Quick Connect Fitting Service .
21. Release the fuel feed pipe (1) from the multiport fuel injection fuel rail (3).
22. Close the fuel feed pipe (1) and the multiport fuel injection fuel rail (3) with CH-807 closure plugs .



23. Remove the positive crankcase ventilation tube (1) from throttle body (3) and the camshaft cover (2). Refer to Plastic Collar Quick Connect Fitting Service .



24. Disconnect the manifold absolute pressure sensor wiring harness plug (5).
25. Remove the clamp (2) and remove the throttle body heater inlet hose (1) from the throttle body (3). Refer to Plastic Collar Quick Connect Fitting Service .
26. Disconnect the throttle body heater outlet hose (4) from the throttle body (3). Refer to Plastic Collar Quick Connect Fitting Service .
27. Remove the engine management wiring harness and the fuel injectors wiring harness.



28. Disconnect the throttle body heater inlet hose connector from the engine coolant thermostat housing (1). Refer to Plastic Collar Quick Connect Fitting Service .
29. Remove the throttle body heater inlet hose (2).
30. Remove the throttle body assembly. Refer to Throttle Body Assembly Replacement : 1.6L LDE, LXV, 1.8L 2H0, and LUW .



31. Remove the 2 multiport fuel injection fuel rail bolts (1).
32. Remove the multiport fuel injection fuel rail (2) and the fuel injectors (4) from the inlet manifold (5).
33. Remove the 4 multiport fuel injector seals (4).



34. Remove the manifold absolute pressure sensor bolt (1).
35. Remove the manifold absolute pressure sensor (2) from the intake manifold (3).



36. Disconnect the servo unit vacuum pipe (2) from the inlet manifold (1).



37. Remove the 7 intake manifold bolts (1).
38. Remove the intake manifold (2).



39. Remove the inlet manifold gaskets (1, 3) from the inlet manifold (2).



40. Remove the rubber bracket (2) from the inlet manifold (1).

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

1. Clean the sealing surfaces.



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



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

Caution: Refer to Fastener Caution in the Preface section.




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



5. Install the manifold absolute pressure sensor (2) to the intake manifold (3).
6. Install the manifold absolute pressure sensor bolt (1) and tighten to 6 N·m (53 lb in).



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



10. Connect the servo unit vacuum pipe (2) to the inlet manifold (1).
11. Install the throttle body assembly. Refer to Throttle Body Assembly Replacement : 1.6L LDE, LXV, 1.8L 2H0, and LUW .



12. Install the throttle body heater inlet hose (2).
13. Connect the throttle body heater inlet hose (2) to the engine coolant thermostat housing (1). Refer to Plastic Collar Quick Connect Fitting Service .



14. Connect the throttle body heater outlet hose (4) to the throttle body (3). Refer to Plastic Collar Quick Connect Fitting Service .
15. Install the throttle body heater inlet hose (1) to the throttle body (3) install the clamp (2).
16. Connect the manifold absolute pressure sensor wiring harness plug (5).
17. Install the engine management wiring harness and the fuel injectors wiring harness.



18. Install the positive crankcase ventilation tube (1) to the throttle body (3) and to the camshaft cover (2). Refer to Plastic Collar Quick Connect Fitting Service .



19. Remove the CH-807 closure plugs from the fuel feed pipe (1) and the multiport fuel injection fuel rail (3).
20. Install the fuel feed pipe (1) to the multiport fuel injection fuel rail (3). Refer to Plastic Collar Quick Connect Fitting Service .
21. Clip the fuel feed pipe (1) into the fuel feed pipe clip (2).



22. Install the evaporative emission canister purge solenoid valve (2) and the rubber mounting to the inlet manifold (4).
23. Install the 2 evaporative emission canister bracket bolts (1) and tighten to 8 N·m (71 lb in).
24. Connect the pipe (5) to the evaporative emission canister purge solenoid valve (2) and to the inlet manifold (4). Refer to Plastic Collar Quick Connect Fitting Service .
25. Connect wiring harness plug (3).



26. Remove the EN-6015 closure plug from the fuel tank vent pipe (1).
27. Install the fuel tank vent pipe (1) to the evaporative emission canister purge solenoid valve (3). Refer to Plastic Collar Quick Connect Fitting Service .
28. Raise the vehicle.



29. Install the intake manifold brace (1).
30. Install the 2 intake manifold brace bolts (2; 3) and tighten to 8 N·m (71 lb in).



31. Install the wiring harness bracket (1) to the inlet manifold (2).
32. Connect the oxygen wiring harness (3).
33. Lower the vehicle.
34. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
35. Install the dash upper extension panel opening cover. Refer to Dash Upper Extension Panel Opening Cover Replacement .
36. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System .
37. Close the bonnet.