GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1999 🢒 Cavalier 🢒 Engine 🢒 Engine Mechanical - 2.2L 🢒 Intake Manifold Replacement

Removal Procedure
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure in Engine Controls - 2.2L

    2. Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  2. Disconnect the negative battery cable.
  3. Remove the air cleaner inlet duct (1).

    4. Object Number: 193392 Size: SH
  4. Remove the resonator.

    5. Object Number: 193394 Size: SH
  5. Remove the resonator bracket.

    6. Object Number: 193395 Size: SH
  6. Remove the following cables:
    7. • The accelerator (2)
    • The cruise control (1)

    Object Number: 193398 Size: SH
  7. Disconnect the vacuum hoses at the throttle body.

    8. Object Number: 193512 Size: SH
  8. Remove the MAP sensor.

    9. Object Number: 193609 Size: SH
  9. Remove the TP sensor.

    10. Object Number: 193612 Size: SH
  10. Remove the IAC sensor.

    11. Object Number: 193401 Size: SH
  11. Remove the two bolts attaching the accelerator bracket.

    12. Object Number: 183480 Size: SH
  12. Remove the throttle body.
  13. Remove the fuel feed.
  14. Remove the fuel inlet pipe retainers.

    15. Object Number: 193410 Size: SH
  15. Remove the intake manifold attaching nuts and the bolts.
  16. Remove the intake manifold from the engine.

    17. Object Number: 182943 Size: SH
  17. Clean the mating surfaces on the intake manifold and the cylinder head.
  18. Inspect the manifold for cracks, broken flanges, and gasket surface damage.

Installation Procedure
  1. Install the intake manifold assembly.

    2. Object Number: 182943 Size: SH
  2. Install the intake manifold to cylinder head bolts and the nuts.

    3. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  3. Install the fuel inlet pipe retainers.

    4. Object Number: 193410 Size: SH

    Tighten
    Tighten the bolts to 24 N·m (18 lb in).

  4. Install the throttle body.

    5. Object Number: 183480 Size: SH
  5. Connect the fuel feed and return quick-connect fittings.
  6. Install the two bolts attaching the accelerator cable bracket.

    7. Object Number: 193401 Size: SH

    Object Number: 193512 Size: SH
  7. Connect the MAP sensor.

    8. Object Number: 193609 Size: SH
  8. Connect the TP sensor.

    9. Object Number: 193612 Size: SH
  9. Connect the IAC sensor.