Spark

Lower Intake Manifold Replacement

1. Remove the upper intake manifold. Refer to Upper Intake Manifold Replacement
2. Remove the multiport fuel injection fuel rail and the fuel injectors from the lower intake manifold. Refer to Fuel Injection Fuel Rail Assembly Replacement



3. Remove the EGR to EGR pipe retaining nuts (3) and EGR pipe bracket to lower intake manifold retaining bolt (2).
4. Remove the EGR pipe (1) and EGR gasket (4).



5. Remove the rear intake manifold bracket to lower intake manifold retaining bolts (2).



6. Disconnect the intake manifold runner control (IMRC) valve actuator hose (3).
7. Disconnect the IMRC valve connector (1) from IMRC valve (2).
8. Remove the bolt (4).
9. Remove the IMRC valve (2).
10. Remove the wiring harness (5) from the lower intake manifold.
11. Lower the vehicle by its full height. Refer to Lifting and Jacking the Vehicle



12. Remove the bolt (1).
13. Remove the rear intake manifold bracket.



14. Remove the 2 nuts (2) and 5 bolts (3).
15. Remove the lower intake manifold (1).

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

Caution: Refer to Fastener Caution in the Preface section.




3. Install the intake manifold (1) and the 5 intake manifold bolts (3) 2 nuts (2) and tighten to 10 N·m (89 lb in).
4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle



5. Install the rear intake manifold and tighten the bolt (1) to 10 N·m (89 lb in).
6. Lower the vehicle.



7. Install the wiring harness (5) to intake manifold retaining hole.
8. Install intake manifold runner control (IMRC) valve (2) with bracket and tighten the bolts (4) to 10 N·m (89 lb in).
9. Connect the IMRC valve connector (1) to IMRC valve (2).
10. Connect the hose (3) to IMRC valve actuator.



11. Install the bolts (2) and tighten to 10 N·m (89 lb in).



12. Install the new EGR pipe gasket.
13. Install the EGR pipe (1) and tighten the nuts (3) to 10 N·m (89 lb in) and the bolts (2) to 10 N·m (89 lb in).
14. Install the multiport fuel injection fuel rail and the fuel injectors to the intake manifold. Refer to Fuel Injection Fuel Rail Assembly Replacement
15. Install the upper intake manifold. Refer to Upper Intake Manifold Replacement
16. Close the bonnet.