GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 1999 🢒 Firefly (Canada) 🢒 Engine 🢒 Engine Mechanical - 1.3L 🢒 Intake Manifold Replacement

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

    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. Drain the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
  4. Remove the air cleaner assembly.
  5. Disconnect the following electrical connectors:
    6. • The ground wires from the intake manifold
    • The fuel injector connectors
    • The manifold absolute pressure (MAP) sensor connector
    • Throttle Position (TP) Sensor
    • Idle Air Control (IAC) Valve
    • EVAP Canister Purge Valve

    Object Number: 262525 Size: SH
  6. Disconnect the wiring harness from the retaining clamps.
  7. Remove the fuel return and the fuel feed hoses from the fuel rail.
  8. Remove the coolant hoses from the throttle body (8) and intake manifold.
  9. Remove the following hoses:
    10. • The canister purge hose from the intake manifold
    • The brake booster hose from the intake manifold
  10. Remove the accelerator cable from the throttle body.
  11. Remove the seven nuts and three bolts from the intake manifold.
  12. Remove the intake manifold (6) with the throttle body (8) and the wire clamps from the cylinder head still attached.
  13. Remove the intake manifold gasket from the cylinder head.

Installation Procedure

    Object Number: 262525 Size: SH
  1. Install the new intake manifold gasket to the cylinder head.

    2. 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.

  2. Install the intake manifold with the TBI unit (8) and wire clamps to the cylinder head still attached. Secure the intake manifold with the two nuts and the seven bolts.

    3. Tighten
    Tighten the intake manifold mounting bolts and nuts to 23 N·m (17 lb ft).

  3. Install the following vacuum hoses:
    4. • The canister purge hose to the intake manifold
    • The brake booster hose from the intake manifold
  4. Install the coolant hoses to the throttle body and the intake manifold.
  5. Install the fuel return and the fuel feed hoses to the fuel rail.
  6. Connect the following electric connectors:
    7. • The ground wires from the intake manifold
    • The fuel injector connector
    • The manifold absolute pressure (MAP) sensor connector
    • Throttle Position (TP) Sensor
    • Idle Air Control (IAC) Valve
    • EVAP Canister Purge Valve
  7. Secure the wiring harness to the retaining clamps.
  8. Install the accelerator cable to the throttle body.
  9. Adjust the accelerator cable play to the specifications. Refer to Accelerator Cable Replacement in Engine Controls.
  10. Install the air cleaner assembly to the throttle body.
  11. Reconnect the negative battery cable.
  12. Refill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  13. Upon completion of the installation, start the engine and check for fuel and engine coolant leaks.