Neon, 2000-2005

Intake Manifold

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Removal & Installation



2.0L SOHC Engine
Except High Output Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Fresh air inlet duct from the air cleaner
     
    Fuel supply line from the fuel tube assembly
     
    Fuel injector cover
     
    Fuel rail assembly
     
    Brake booster vacuum hose
     
    Positive Crankcase Ventilation (PCV) hose
     
    Knock Sensor (KS) electrical connector
     
    Starter wiring connectors
     
    Intake manifold and discard the gasket
     

  6.  
  7. Clean all mating surfaces of any residual gasket material.
  8.  

To install:

Click image to see an enlarged view

Fig. Intake manifold bolt torque sequence-2.0L (VIN C) SOHC engine

Intake manifold bolt torque sequence-2.0L (VIN C) SOHC engine

  1. Install or connect the following:

    New gaskets and seals
     
    Intake manifold and torque the new retainers, in sequence, to 95 inch lbs. (11 Nm)
     
    Fuel rail and torque the screws to 17 ft. lbs. (23 Nm)
     
    PCV hose
     
    Brake booster hose
     

  2.  
  3. Inspect the fuel line quick-connect fittings for damage and replace if necessary. Apply a small amount of clean engine oil to the fuel inlet tube.

    Fuel supply hose to the fuel rail assembly. Ensure the connection is fastened securely by pulling on the connector.
     
    Fuel injector cover
     
    MAP sensor wiring
     
    KS sensor connector
     
    Air inlet duct
     
    Negative battery cable
     

  4.  
  5. Start the vehicle, check for leaks and repair if necessary.

    Click image to see an enlarged view

    Fig. View of the intake manifold lower supports-SOHC engines

    View of the intake manifold lower supports-SOHC engines

    Click image to see an enlarged view

    Fig. View of the Manifold Absolute Pressure (MAP) sensor-SOHC engines

    View of the Manifold Absolute Pressure (MAP) sensor-SOHC engines

    Click image to see an enlarged view

    Fig. View of the Knock Sensor (KS)-SOHC engines

    View of the Knock Sensor (KS)-SOHC engines
  6.  

High Output Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:
    CAUTION
    Wrap towels around the fitting to catch any spilled fuel.



    Negative battery cable
     



    Fuel supply line quick-connect from the fuel tube assembly
     
    Fuel rail cover from the engine
     
    Fuel injector connector and harness from the injectors and fuel rail
     
    Positive Crankcase Ventilation (PCV) hose
     
    Throttle body-to-intake manifold air duct
     
    Lower intake manifold support bracket bolt
     
    Oil dipstick
     
    Manifold Absolute Pressure (MAP) sensor wiring
     
    Manifold Tuning Valve (MTV) actuator wiring
     
    Intake manifold-to-cylinder head bolts and move the manifold forward
     
    Knock (KS) Sensor wiring
     
    Brake booster hose
     
    Intake manifold and discard the gasket
     

  6.  
  7. If necessary, separate the upper manifold from the lower manifold.
  8.  

To install:

Click image to see an enlarged view

Fig. Lower intake manifold bolt torque sequence-High Output 2.0L (VIN F) SOHC engine

Lower intake manifold bolt torque sequence-High Output 2.0L (VIN F) SOHC engine

Click image to see an enlarged view

Fig. Upper intake manifold bolt torque sequence-High Output 2.0L (VIN F) SOHC engine

Upper intake manifold bolt torque sequence-High Output 2.0L (VIN F) SOHC engine

  1. Clean the mating surfaces of any residual gasket material.
  2.  
  3. Install or connect the following:

    Lower manifold to the upper manifold with a new gasket and torque the bolts to 105 inch lbs. (12 Nm)
     
    Intake manifold on the cylinder head with a new gasket
     
    Engine wiring harness between the middle intake runners
     
    KS wiring connector
     
    Brake booster hose and torque the intake manifold bolts, in sequence, to 105 inch lbs. (12 Nm)
     
    Lower manifold support bracket bolt and torque the bolt to 21 ft. lbs. (28 Nm)
     
    MAP sensor connector
     
    MTV actuator connector
     
    Oil dipstick
     
    Inlet air duct to the manifold and the throttle body
     
    PCV hose
     
    Fuel injector connectors and harness to the fuel rail
     
    Fuel rail cover
     
    Fuel supply line
     
    Negative battery cable
     

  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

 
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