Metro, Prizm 2000-2002

Intake Manifold

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Removal & Installation



  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Accelerator cable from the throttle body
     
    Throttle valve cable from the throttle body, if equipped
     
    Intake Air Temperature (IAT) sensor electrical connector
     
    Air cleaner assembly
     
    Throttle Position (TPS) sensor electrical connector
     
    Idle Air Control (IAC) valve electrical connector
     
    Manifold Absolute Pressure (MAP) sensor electrical connector
     
    Coolant bypass hoses
     
    Fuel injector electrical connectors
     
    Wiring harness from the intake manifold
     
    Intake manifold support bracket
     
    Upper radiator hose and support bracket
     
    Brake booster vacuum hose
     
    Fuel feed and return hoses
     
    Intake manifold
     

  8.  

To install:

  1. Install or connect the following:

    Intake manifold with a new gasket and torque the bolts to 13 ft. lbs. (18 Nm)
     
    Brake booster vacuum hose
     
    Fuel inlet pipe to the fuel rail and torque the fitting to 22 ft. lbs. (29 Nm)
     
    Fuel return hose
     
    Intake manifold support bracket and torque the bolts to 13 ft. lbs. (18 Nm)
     
    Upper radiator hose and support bracket and torque the bolt to 13 ft. lbs. (18 Nm)
     
    Engine wire harness to the intake manifold and torque the bolt to 9 ft. lbs. (13 Nm)
     
    Fuel injector connectors to the fuel injectors
     
    Coolant bypass hoses
     
    MAP sensor electrical connector
     
    IAC valve electrical connector
     
    TPS sensor electrical connector
     
    Air cleaner assembly
     
    IAT sensor electrical connector
     
    Accelerator cable and torque the bolts to 98 inch lbs. (11 Nm)
     
    Throttle valve cable, if equipped and torque the bolts to 11 ft. lbs. (15 Nm)
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the vehicle and check for leaks, repair if necessary.
  6.  

1.0L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Air cleaner
     
    Engine Coolant Temperature (ECT) sensor electrical connector
     
    ECT sending unit connector
     
    Throttle Position (TPS) sensor electrical connector
     
    Exhaust Gas Recirculation (EGR) valve electrical connector
     
    Idle Speed Control (ISC) motor electrical connector
     
    Ground wires from the intake manifold
     
    Throttle body electrical connector
     
    Manifold Absolute Pressure (MAP) sensor electrical connector
     
    Early Fuel Evaporative (EFE) heater electrical connector, if equipped
     
    Fuel feed and return hoses from the throttle body
     
    Coolant hoses from the throttle body
     
    EGR Modulator
     
    EGR valve
     
    Evaporative Emissions (EVAP) canister vacuum hose
     
    MAP sensor hose from the intake manifold
     
    Brake booster vacuum hose
     
    Positive Crankcase Ventilation (PCV) vacuum hose
     
    Accelerator cable from the throttle body
     
    Intake manifold/throttle body unit
     

  8.  

To install:

  1. Install or connect the following:

    Intake manifold with a new gasket and torque the bolts to 17 ft. lbs. (23 Nm)
     
    PCV hose
     
    EVAP canister vacuum hose
     
    MAP sensor vacuum hose
     
    Brake booster vacuum hose
     
    Coolant hoses
     
    Fuel feed and return hoses
     
    ECT sensor electrical connector
     
    Coolant temperature sending unit electrical connector
     
    EFE heater electrical connector, if equipped
     
    ECT switch electrical connector
     
    TPS sensor electrical connector
     
    EGR solenoid valve electrical connector
     
    ISC motor electrical connector
     
    Ground wires to the intake manifold
     
    Throttle body electrical connector
     
    Wiring harness to the retaining clamps
     
    Accelerator cable to the throttle body and adjust as needed
     
    Air cleaner assembly
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the vehicle and check for leaks, repair if necessary.
  6.  

1.3L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Air cleaner
     
    Ground wires from the intake manifold
     
    Fuel injector electrical connectors
     
    Manifold Absolute Pressure (MAP) sensor electrical connector
     
    Throttle Position (TPS) sensor electrical connector
     
    Idle Air Control (IAC) valve electrical connector
     
    Evaporative Emissions (EVAP) canister purge valve electrical connector
     
    Wiring harness from the retaining clamps
     
    Fuel feed and return hoses
     
    Coolant hoses from the throttle body
     
    Brake booster hose
     
    Canister purge hose
     
    Accelerator cable
     
    Intake manifold bolts
     
    Intake manifold
     

  8.  

To install:

  1. Install or connect the following:

    Intake manifold with a new gasket and torque the nuts and bolts to 17 ft. lbs. (23 Nm)
     
    Canister purge hose
     
    Brake booster hose
     
    Coolant hoses
     
    Fuel feed and return hoses
     
    Wiring harness to the retaining clamps
     
    Ground wires to the intake manifold
     
    Fuel injector electrical connectors
     
    MAP sensor electrical connector
     
    TPS sensor electrical connector
     
    IAC valve electrical connector
     
    EVAP canister purge valve electrical connector
     
    Accelerator cable
     
    Air cleaner assembly
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the vehicle and check for leaks, repair as necessary.
  6.  

 
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