ION 2006-2007

Intake Manifold

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Removal & Installation



2.0L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the supercharger.
  6.  
  7. Remove the alternator.
  8.  
  9. Drain the charged air cooling system.
  10.  
  11. Disconnect the charged air cooling system inlet and outlet hoses.
  12.  
  13. Remove the charged air coolant pump.
  14.  
  15. Remove the cooling fan assembly.
  16.  
  17. Remove the AC compressor bolts and reposition the compressor to access the oil level indicator tube.
  18.  
  19. Remove the oil level indicator tube bolt.
    NOTE
    Be sure to remove all fasteners before attempting to remove the intake manifold.

  20.  
  21. Remove the intake manifold nuts and bolts.
  22.  
  23. Remove the intake manifold.
    NOTE
    The intake manifold gasket is reusable, only replace the gasket if damage has occurred.

  24.  
  25. If applicable, remove the intake manifold gasket.
  26.  

To install:

  1. If applicable, install the intake manifold gasket.
  2.  
  3. Install the intake manifold.
  4.  
  5. Install the intake manifold nuts and bolts. Tighten to 89 inch lbs. (10 Nm).
  6.  
  7. Install the oil level indicator tube and bolt.
  8.  
  9. Reposition the AC compressor and install the bolts and tighten to 16 ft. lbs. (22 Nm).
  10.  
  11. Install the cooling fan assembly.
  12.  
  13. Install the charged air coolant pump.
  14.  
  15. Install the alternator.
  16.  
  17. Connect the charged air cooling system inlet and outlet hoses.
  18.  
  19. Fill the charged air cooling system.
  20.  
  21. Install the supercharger.
  22.  
  23. Connect the negative battery cable.
  24.  

2.2L Engines
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner assembly
     
    Idle Air Control (IAC) valve electrical connectors
     
    Throttle Position Sensor (TPS) electrical connectors
     
    Vacuum hoses from the throttle body
     
    Throttle control cable and bracket
     
    Throttle body
     
    Positive Crankcase Valve (PCV) hose
     
    Purge solenoid tube
     
    Brake booster hose
     
    Oil dipstick tube bolt
     
    Fuel rail
     
    Knock Sensor (KS) connector
     
    Intake manifold bolts and nuts
     
    Intake manifold
     

  4.  

To install:

  1. Install or connect the following:

    Intake manifold with a new gasket and torque the nuts to 89 inch lbs. (10 Nm) starting from the center and working outward
     
    Knock Sensor (KS) connector
     
    Fuel rail
     
    Oil dipstick tube bolt
     
    Brake booster hose
     
    Purge solenoid tube
     
    PCV hose
     
    Throttle body to the intake manifold and torque the bolts to 89 inch lbs. (10 Nm)
     
    Throttle cable bracket and torque the bolts to 89 inch lbs. (10 Nm)
     
    Throttle cable
     
    IAC sensor electrical connector
     
    TPS electrical connectors
     
    Vacuum hoses from the throttle body
     
    Air cleaner assembly
     
    Negative battery cable
     

  2.  
  3. Start the engine, check for leaks, and repair if necessary.
  4.  

 
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