GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Aveo 🢒 Engine 🢒 Engine Controls - 1.6L (L91) 🢒 Intake Manifold Replacement

Removal Procedure

    Object Number: 1291944 Size: SH
  1. Remove the fuel pump fuse.
  2. Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of fuel pressure.

    3. Caution: Refer to Battery Disconnect Caution in the Preface section.

  3. Disconnect the negative battery cable.

    4. Caution: Refer to Safety Glasses Caution in the Preface section.

  4. Drain the engine coolant. Refer to Cooling System Draining and Filling .

    5. Object Number: 1371852 Size: SH
  5. Disconnect the intake air temperature (IAT) sensor connector.
  6. Disconnect the air intake tube from the throttle body.

    7. Object Number: 1371861 Size: SH
  7. Disconnect the idle air control (IAC) valve connector.
  8. Disconnect the throttle position sensor (TPS) connector.
  9. Remove the alternator adjusting bolt and the alternator drive belt.
  10. Disconnect the engine coolant temperature (ECT) sensor connector.
  11. Disconnect the heater inlet hose from the cylinder head.
  12. Disconnect the surge tank coolant hose at the throttle body.

    13. Object Number: 1371862 Size: SH
  13. Disconnect all of the necessary vacuum hoses, including the vacuum hose at the fuel pressure regulator and the brake boaster vacuum hose at the intake manifold.
  14. Disconnect the throttle body cable from the throttle body and the intake manifold.

    15. Object Number: 1371868 Size: SH
  15. Remove the fuel injector rail and fuel injectors as an assembly.
  16. Remove the alternator adjusting bracket bolt from the intake manifold.
  17. Remove the alternator adjusting bracket.
  18. Remove the intake manifold support bracket bolts and the intake manifold.
  19. Remove the intake manifold support bracket.

    20. Object Number: 1371919 Size: SH
  20. Remove the intake manifold retaining nuts/bolts in the sequence shown.
  21. Remove the intake manifold.
  22. Remove the intake manifold gasket.
  23. Clean the sealing surfaces of the intake manifold and the cylinder head.

    24. Object Number: 1291155 Size: SH
  24. Remove the alternator. Refer to Generator Replacement .
  25. Remove the intake manifold support bracket.

Installation Procedure

    Object Number: 1371920 Size: SH
  1. Install the intake manifold gasket.
  2. Install the intake manifold.

    3. Notice: Refer to Fastener Notice in the Preface section.

  3. Install the intake manifold retaining nuts/bolts in the sequence shown.

    4. Tighten
    Tighten the intake manifold retaining nuts/bolts to 25 N·m (18 lb ft).


    Object Number: 1371868 Size: SH
  4. Install the intake manifold support bracket.
  5. Install the intake manifold support bracket upper bolts to the intake manifold.

    6. Tighten
    Tighten the intake manifold support bracket upper bolts to 25 N·m (18 lb ft).

  6. Install the intake manifold support bracket lower bolt-to-engine block.

    7. Tighten
    Tighten the intake manifold support bracket lower bolt-to-engine block to 40 N·m (30 lb ft).


    Object Number: 1371862 Size: SH
  7. Install the fuel rail and fuel injectors as an assembly.
  8. Connect the throttle cable to the intake manifold and the throttle body.
  9. Connect all of the necessary vacuum lines that were previously disconnected.
  10. Connect the heater inlet hose to the cylinder head.
  11. Connect the surge tank coolant hose to the throttle body.
  12. Install the alternator adjusting bracket at the intake manifold.

    13. Object Number: 1371861 Size: SH
  13. Install the alternator adjusting bracket bold.

    14. Tighten
    Tighten the alternator adjusting bracket bolts to 15 N·m (11 lb ft).

  14. Install the alternator adjusting bolt and the alternator drive belt.

    15. Tighten
    Tighten the alternator adjusting bolts to 15 N·m (11 lb ft).

  15. Connect the ECT sensor connector.
  16. Connect the IAC valve connector.
  17. Connect the TPS connector.

    18. Object Number: 1371852 Size: SH
  18. Connect the air intake tube to the throttle body.
  19. Connect the IAT sensor connector.
  20. Connect the powertrain control module (PCM)/engine control module (ECM) ground terminal to the intake manifold.
  21. Install the fuel pump fuse.
  22. Connect the negative battery cable.
  23. Refill the engine cooling system. Refer to Cooling System Draining and Filling .