Chevrolet Sonic manuals

Chevrolet Sonic Repair Manual: Intake Manifold Replacement

Special Tools

For equivalent regional tools, refer to Special Tools

Removal Procedure
  1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
  2. Remove the engine sight shield.

  3. Unclip the heater outlet hose from retainer clip (1).
  4. Unclip the engine control module wiring harness from 2 retainer clips (2).
  5. Lower the vehicle.
  6. Remove the charge air cooler outlet air hose from the throttle body. Refer to Charge Air Cooler Outlet Air Hose Replacement.


  7. Disconnect the throttle body wiring harness plug (1).

  8. Disconnect the evaporative emission canister purge solenoid valve wiring harness plug (2).
  9. Disconnect the manifold absolute pressure sensor wiring harness plug (1).
  10. Disconnect the 4 fuel injector wiring harness plugs (4).
  11. Unclip the engine control module wiring harness from the camshaft cover.
  12. Disconnect the PCV hose (3).

  13. Disconnect the turbocharger wastegate regulator solenoid valve wiring harness plug (3).
  14. Unclip the engine control module wiring harness from 2 intake manifold retainer clips (2) and from 2 fuel injection rail retainer clips (1).
  15. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.


  16. Remove the fuel feed pipe (4) from fuel injector rail.
  17. Unclip the fuel feed pipe from retainer clip (1).
  18. Remove the fuel ventilation pipe (2) from evaporative emission canister purge solenoid valve.
  19. Unclip the fuel ventilation pipe from retainer clip (1).
  20. Close the vents with the EN-6015 closure plugs.
  21. Disconnect the brake booster vacuum pipe (3) from the intake manifold.

  22. Note:

    The intake manifold bolts remain in intake manifold.

  23. Remove the 6 intake manifold bolts (1).

  24. Remove the intake manifold (1) and the intake manifold gasket.
  25. Transfer parts from intake manifold as necessary. Refer to Intake Manifold Disassemble and Intake Manifold Assemble.
Installation Procedure
  1. Clean the sealing surfaces.

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

  3. Caution:

    Refer to Fastener Caution.

  4. Install the 6 intake manifold bolts (1) and tighten to 20 Y (15 lb ft)

    .



  5. Connect the fuel ventilation pipe (2) to the evaporative emission canister purge solenoid valve.
  6. Clip in the fuel ventilation pipe to the retainer clip (1).
  7. Connect the fuel feed pipe (4) to the injector rail.
  8. Clip in the fuel feed pipe to the retainer clip (1).
  9. Connect the brake booster vacuum pipe (3) to the intake manifold.

  10. Connect the turbocharger wastegate regulator solenoid valve wiring harness plug (3).
  11. Clip in the engine control module wiring harness to 2 intake manifold retainer clips (2) and from 2 fuel injection rail retainer clips (1).

  12. Clip in the engine control module wiring harness to the camshaft cover.
  13. Connect the 4 fuel injector wiring harness plugs (4).
  14. Connect the manifold absolute pressure sensor wiring harness plug (1) .
  15. Disconnect the evaporative emission canister purge solenoid valve wiring harness plug (2).
  16. Connect the PCV hose (3).

  17. Connect the throttle body wiring harness plug (1).
  18. Install the charge air cooler outlet air hose to the throttle body. Refer to Charge Air Cooler Outlet Air Hose Replacement.
  19. Raise and support the vehicle.

  20. Clip in the heater outlet hose to retainer clip (1).
  21. Clip in the engine control module wiring harness to 2 retainer clips (2).
  22. Install the engine sight shield.
  23. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
Intake Manifold Removal (1.8L LUW and LWE)
Remove the 2 intake manifold brace bolts (2, 3). Remove the intake manifold brace (1). Remove the 7 intake manifold bolts (1). Remove the int ...

Intake Manifold Replacement (LDE)
Removal Procedure Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. Remove the throttle body assembly. Refer to Throttle Body As ...

Other materials:

Securing an Add-On Child Restraint in the Vehicle
Warning A child can be seriously injured or killed in a crash if the child restraint is not properly secured in the vehicle. Secure the child restraint properly in the vehicle using the vehicle safety belt or LATCH system, following the instructions that came with that child restraint and the ...

Steps for Determining Correct Load Limit
1. Locate the statement "The combined weight of occupants and cargo should never exceed XXX kg or XXX lbs." on your vehicle’s placard. 2. Determine the combined weight of the driver and passengers that will be riding in your vehicle. 3. Subtract the combined weight of the driver an ...

Front Seat Belt Anchor Plate Tensioner Cover Replacement (4 Way)
Front Seat Belt Anchor Plate Tensioner Cover Replacement Callout Component Name 1 Driver or Passenger Seat Belt Tensioner Cover Procedure Remove the tensioner cover by pushing downward on the rear and center o ...

© 2014-2019 Copyright www.csmans.com
   
0.0121