Chevrolet Sonic Repair Manual: Intake Manifold Replacement
Special Tools
- EN-34730?E1 Pressure Tester
- EN-6015 Closure Plugs
For equivalent regional tools, refer to Special Tools
- Removal Procedure
-
- Disconnect the battery negative cable. Refer to Battery Negative Cable
Disconnection and Connection.
- Remove the engine sight shield.
- Unclip the heater outlet hose from retainer clip (1).
- Unclip the engine control module wiring harness from 2 retainer clips (2).
- Lower the vehicle.
- Remove the charge air cooler outlet air hose from the throttle body.
Refer to Charge Air Cooler Outlet Air Hose Replacement.
- Disconnect the throttle body wiring harness plug (1).
- Disconnect the evaporative emission canister purge solenoid valve wiring
harness plug (2).
- Disconnect the manifold absolute pressure sensor wiring harness plug (1).
- Disconnect the 4 fuel injector wiring harness plugs (4).
- Unclip the engine control module wiring harness from the camshaft cover.
- Disconnect the PCV hose (3).
- Disconnect the turbocharger wastegate regulator solenoid valve wiring
harness plug (3).
- Unclip the engine control module wiring harness from 2 intake manifold
retainer clips (2) and from 2 fuel injection rail retainer clips (1).
- Relieve the fuel system pressure. Refer to Fuel Pressure Relief.
- Remove the fuel feed pipe (4) from fuel injector rail.
- Unclip the fuel feed pipe from retainer clip (1).
- Remove the fuel ventilation pipe (2) from evaporative emission canister
purge solenoid valve.
- Unclip the fuel ventilation pipe from retainer clip (1).
- Close the vents with the EN-6015 closure plugs.
- Disconnect the brake booster vacuum pipe (3) from the intake manifold.
Note:
The intake manifold bolts remain in intake manifold.
- Remove the 6 intake manifold bolts (1).
- Remove the intake manifold (1) and the intake manifold gasket.
- Transfer parts from intake manifold as necessary. Refer to Intake Manifold
Disassemble and Intake Manifold Assemble.
- Installation Procedure
-
- Clean the sealing surfaces.
- Install the intake manifold (1) along with a NEW intake manifold gasket.
Caution:
Refer to Fastener Caution.
- Install the 6 intake manifold bolts (1) and tighten to 20 Y (15 lb ft)
.
- Connect the fuel ventilation pipe (2) to the evaporative emission canister
purge solenoid valve.
- Clip in the fuel ventilation pipe to the retainer clip (1).
- Connect the fuel feed pipe (4) to the injector rail.
- Clip in the fuel feed pipe to the retainer clip (1).
- Connect the brake booster vacuum pipe (3) to the intake manifold.
- Connect the turbocharger wastegate regulator solenoid valve wiring harness
plug (3).
- Clip in the engine control module wiring harness to 2 intake manifold
retainer clips (2) and from 2 fuel injection rail retainer clips (1).
- Clip in the engine control module wiring harness to the camshaft cover.
- Connect the 4 fuel injector wiring harness plugs (4).
- Connect the manifold absolute pressure sensor wiring harness plug (1)
.
- Disconnect the evaporative emission canister purge solenoid valve wiring
harness plug (2).
- Connect the PCV hose (3).
- Connect the throttle body wiring harness plug (1).
- Install the charge air cooler outlet air hose to the throttle body.
Refer to Charge Air Cooler Outlet Air Hose Replacement.
- Raise and support the vehicle.
- Clip in the heater outlet hose to retainer clip (1).
- Clip in the engine control module wiring harness to 2 retainer clips (2).
- Install the engine sight shield.
- Connect the battery negative cable. Refer to Battery Negative Cable
Disconnection and Connection.
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 ...
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:
Forward Collision Alert (FCA) Warning Light
These lights are on the center of the instrument panel.
The vehicle ahead light comes on when a vehicle is detected ahead and a possible
collision can occur.
The forward collision alert comes on when following a vehicle much too closely.
The light flashes when a vehicle is being rapidly ap ...
Rear Wheelhouse Liner Replacement (Sedan - Right)
Rear Wheelhouse Liner Replacement
Callout
Component Name
Preliminary Procedure
Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and
Installation.
1
Rear Wheelhouse Panel Liner ...
Wiper/Washer System Description and Operation
Wiper/Washer System Components
The wiper/washer system consists of the following electrical components:
Windshield Wiper Relay
Windshield Wiper Speed Control Relay
Windshield Washer Pump Relay
Windshield Washer Pump
Windshield Wiper Motor
Windshield Wiper/Washer Switch
...
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