Volt

Inlet Manifold Replacement

Special Tools

BO-38185 Hose Clamp Pliers

For equivalent regional tools, refer to Special Tools .

Danger: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.

The High Voltage Disabling procedure will perform the following tasks:

•	Identify how to disable high voltage.

•	Identify how to test for the presence of high voltage.

•	Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.

Failure to follow the procedures exactly as written may result in serious injury or death.
1. Disable the high voltage system. Refer to High Voltage Disabling .
2. Remove the Air Cleaner Outlet Duct. Refer to Air Cleaner Outlet Duct Replacement .
3. Remove the fuel injection fuel rail assembly only. Refer to Fuel Injection Fuel Rail Assembly Replacement



4. Remove the evaporative emission canister purge solenoid valve hose (1). Refer to Plastic Collar Quick Connect Fitting Service .
5. Unclip and reposition the engine coolant air bleed hose without draining coolant. Refer to Engine Coolant Air Bleed Hose Connector Replacement



6. Remove the inlet manifold bolts (1).



7. Remove the inlet manifold from the vehicle (1).
8. Disconnect electrical connectors as necessary.
9. To disassemble the inlet manifold. Refer to Inlet Manifold Disassemble
10. For cleaning and inspection of the inlet manifold. Refer to Inlet Manifold Cleaning and Inspection .
11. Transfer components as necessary.

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



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

Caution: Refer to Fastener Caution in the Preface section.




4. Install the inlet manifold bolts (1).

Tighten
Tighten the inlet manifold bolts 20 N·m (15 lb ft).




5. Install the evaporative emission canister purge solenoid valve hose (1). Refer to Plastic Collar Quick Connect Fitting Service .
6. Install the fuel injection fuel rail assembly only. Refer to Fuel Injection Fuel Rail Assembly Replacement .
7. Install the Air Cleaner Outlet Duct. Refer to Air Cleaner Outlet Duct Replacement .
8. Fill the coolant fluid. Refer to Cooling System Draining and Filling .
9. Enable the high voltage system. Refer to High Voltage Enabling .