Captiva

Inlet Manifold Replacement

Special Tools

BO-38185 Hose Clamp Pliers

For equivalent regional tools, refer to Special Tools .

1. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Drain the coolant fluid. Refer to Cooling System Draining and Filling .
3. Remove the fuel injection fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement .



4. Remove the surge tank overflow hose. Refer to Radiator Surge Tank Overflow Hose Replacement .
5. Disconnect the following:

•	EGR vacuum solenoid (1)

•	EGR valve (2)

•	Intake actuator assembly (3)

•	Engine harness conduit (4)




6. Remove the vacuum pump hose (1) and the manifold intake tuning valve hose (2).
7. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .



8. Remove the transmission mount bracket. Refer to Transmission Mount Bracket Replacement - Rear : FWD  → AWD .
9. Remove the EGR manifold cooling return hose (1) and the EGR valve cooling feed hose (2) , from the EGR cooler.



10. Remove the EGR pipe bolts (1), gasket (2) and seal (3).



11. Remove the EGR cooler support bracket bolt (1).




Note: The EGR cooler brace nut can be accessed from the side of the brace with a 1/4 inch extension and a swivel adapter.

12. Remove the EGR cooler brace nut (2).



13. Remove the EGR valve mounting bolts (1).



14. Remove the EGR valve and the EGR cooler (2) as one assembly.
15. Discard the EGR valve gasket (1).
16. Remove the turbocharger coolant return pipe. Refer to Turbocharger Coolant Return Pipe Replacement : LNQ .
17. Mark the location of the vacuum hoses.
18. Disconnect vacuum lines as necessary.
19. Remove the intake air tuning valve vacuum control solenoid valve. Refer to Inlet Air Tuning Valve Vacuum Control Solenoid Valve Replacement .



20. Remove the intake bolt (2) and nut (1).



21. Remove the intake manifold from the vehicle (1).
22. Disconnect electrical connectors as necessary.
23. Clean and inspect the intake manifold.
24. Transfer components as necessary.

1. Ensure the surface of the intake manifold is clean before installing the new gasket.
2. Install the manifold gasket (1).



3. Install the intake manifold in the vehicle (1).

Caution: Refer to Fastener Caution in the Preface section.




4. Install the intake manifold assembly retaining bolts (2) and nuts (1) and tighten to 25 N·m (18 lb ft).
5. Install the intake air tuning valve vacuum control solenoid valve. Refer to Inlet Air Tuning Valve Vacuum Control Solenoid Valve Replacement .
6. Connect vacuum lines as necessary.



7. Position the EGR valve and cooler assembly (2) to the cylinder head with a NEW gasket (1).



8. Install the EGR valve assembly bolts (1) and tighten to 25 N·m (18 lb ft).



9. Install the EGR cooler brace nut (2) to the cylinder head and tighten to 25 N·m (18 lb ft).




Note: The EGR cooler support nut can be accessed from the side of the brace with a 1/4 inch extension and a swivel adapter.

10. Install the EGR cooler support nut (1) to the cylinder head and tighten to 25 N·m (18 lb ft).



11. Install the EGR manifold cooling return hose (1) and the EGR valve cooling feed hose (2).



12. Install the EGR pipe (4) to the intake manifold and EGR valve with a NEW gasket (2) and seal (3).
13. Tighten the bolts (1) to 25 N·m (18 lb ft).



14. Install the vacuum pump hose (1) and the manifold tuning valve hose (2).
15. Install the surge tank overflow hose. Refer to Radiator Surge Tank Overflow Hose Replacement .



16. Position the engine harness conduit (4) onto the EGR cooler tabs.
17. Connect the following:

•	EGR valve regulator solenoid (1)

•	EGR valve (2)

•	Intake actuator assembly (3)

•	Engine harness conduit (4)

18. Install the fuel injection fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement .
19. Fill the coolant fluid. Refer to Cooling System Draining and Filling .
20. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .