GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Captiva Sport 🢒 Hybrid 🢒 Hybrid Controls - HP5 🢒 Upper Intake Manifold Replacement

Removal Procedure

    Object Number: 1887829 Size: SH
  1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  2. Disconnect the wiring harness electrical connector (3) from the throttle body (4).

    3. Object Number: 1897768 Size: SH
  3. Disconnect the PCV line (1) from the top of the intake manifold and reposition aside.

    4. Object Number: 1898314 Size: SH
  4. Disconnect the evaporative emissions (EVAP) canister purge line (1) and reposition aside.

    5. Object Number: 1898395 Size: SH
  5. Disconnect the coolant hose bleed pipe.
  6. Remove the engine harness retaining clips (1) from the bleed pipe.
  7. Remove the bleed pipe bolts (2).
  8. Remove the bleed pipe hose clamp (3).
  9. Reposition the bleed pipe.
  10. Remove the brake booster vacuum hose from the intake manifold.

    11. Object Number: 1887829 Size: SH
  11. Disconnect the manifold air pressure (MAP) sensor electrical connector from the map sensor (1).

    12. Object Number: 1888937 Size: SH
  12. Remove the EVAP purge solenoid valve bolt (1).

    13. Object Number: 1899129 Size: SH
  13. Remove the engine harness bracket bolt (1).

    14. Object Number: 1899156 Size: SH
  14. Remove the upper intake retaining bolts (1).
  15. Remove the upper intake manifold and gasket. Discard the gasket.
  16. If replacing the upper intake manifold complete the following steps:
    17. 16.1. Remove the evaporative emissions (EVAP) purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement .
    16.2. Remove the throttle body. Refer to Throttle Body Assembly Replacement .

Installation Procedure

    Object Number: 1899156 Size: SH
  1. Install the upper intake manifold gaskets to the lower intake manifold and install the fir tree retainers to retain the upper intake manifold gasket position.
  2. Install the upper intake manifold.
  3. Apply threadlock to the bolt threads. Refer to Adhesives, Fluids, Lubricants, and Sealers .

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

  4. Install the upper intake manifold bolts (1).

    5. Tighten
    Tighten the bolts to 25 N·m (18 lb ft).

  5. If the upper manifold was replaced, complete the following steps:
    6. 5.1. Install the throttle body. Refer to Throttle Body Assembly Replacement .
    5.2. Install the EVAP purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement .

    Object Number: 1899129 Size: SH
  6. Install the engine harness bracket bolt (1).

    7. Object Number: 1888937 Size: SH
  7. Install the EVAP purge solenoid valve bolt (1).

    8. Tighten
    Tighten the bolt to 10 N·m (89 lb in).


    Object Number: 1887829 Size: SH
  8. Connect the manifold air pressure (MAP) sensor electrical connector to the map sensor (1).

    9. Object Number: 1898395 Size: SH
  9. Install the brake booster vacuum hose to the intake manifold.
  10. Position the bleed pipe.
  11. Install the bleed pipe hose clamp (3).
  12. Install the bleed pipe bolts (2).

    13. Tighten
    Tighten the nut to 10 N·m (89 lb in).

  13. Install the engine harness retaining clips (1) to the fuel feed pipe.
  14. Connect the coolant hose bleed pipe.

    15. Object Number: 1898314 Size: SH
  15. Connect the EVAP canister purge line (1).

    16. Object Number: 1897768 Size: SH
  16. Connect the PCV line (1) to the top of the intake manifold .

    17. Object Number: 1887829 Size: SH
  17. Connect the wiring harness electrical connector (3) to the throttle body (4).
  18. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .

Removal Procedure

    Object Number: 1887829 Size: SH
  1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.
  2. Disconnect the wiring harness electrical connector (3) from the throttle body (4).

    3. Object Number: 1897768 Size: SH
  3. Disconnect the PCV line (1) from the top of the intake manifold and reposition aside.

    4. Object Number: 1898314 Size: SH
  4. Disconnect the evaporative emissions (EVAP) canister purge line (1) and reposition aside.

    5. Object Number: 1898395 Size: SH
  5. Disconnect the coolant hose bleed pipe.
  6. Remove the engine harness retaining clips (1) from the bleed pipe.
  7. Remove the bleed pipe bolts (2).
  8. Remove the bleed pipe hose clamp (3).
  9. Reposition the bleed pipe.
  10. Remove the brake booster vacuum hose from the intake manifold.

    11. Object Number: 1887829 Size: SH
  11. Disconnect the manifold air pressure (MAP) sensor electrical connector from the map sensor (1).

    12. Object Number: 1888937 Size: SH
  12. Remove the EVAP purge solenoid valve bolt (1).

    13. Object Number: 1899129 Size: SH
  13. Remove the engine harness bracket bolt (1).

    14. Object Number: 1899156 Size: SH
  14. Remove the upper intake retaining bolts (1).
  15. Remove the upper intake manifold and gasket. Discard the gasket.
  16. If replacing the upper intake manifold complete the following steps:
    17. 16.1. Remove the evaporative emissions (EVAP) purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement.
    16.2. Remove the throttle body. Refer to Throttle Body Assembly Replacement.

Installation Procedure

    Object Number: 1899156 Size: SH
  1. Install the upper intake manifold gaskets to the lower intake manifold and install the fir tree retainers to retain the upper intake manifold gasket position.
  2. Install the upper intake manifold.
  3. Apply threadlock to the bolt threads. Refer to Adhesives, Fluids, Lubricants, and Sealers.

    4. Caution: Refer to Fastener Caution in the Preface section.

  4. Install the upper intake manifold bolts (1) and tighten to 25 N·m (18 lb ft).
  5. If the upper manifold was replaced, complete the following steps:
    6. 5.1. Install the throttle body. Refer to Throttle Body Assembly Replacement.
    5.2. Install the EVAP purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement.

    Object Number: 1899129 Size: SH
  6. Install the engine harness bracket bolt (1).

    7. Object Number: 1888937 Size: SH
  7. Install the EVAP purge solenoid valve bolt (1) and tighten to 10 N·m (89 lb in).

    8. Object Number: 1887829 Size: SH
  8. Connect the manifold air pressure (MAP) sensor electrical connector to the map sensor (1).

    9. Object Number: 1898395 Size: SH
  9. Install the brake booster vacuum hose to the intake manifold.
  10. Position the bleed pipe.
  11. Install the bleed pipe hose clamp (3).
  12. Install the bleed pipe bolts (2) and tighten to 10 N·m (89 lb in).
  13. Install the engine harness retaining clips (1) to the fuel feed pipe.
  14. Connect the coolant hose bleed pipe.

    15. Object Number: 1898314 Size: SH
  15. Connect the EVAP canister purge line (1).

    16. Object Number: 1897768 Size: SH
  16. Connect the PCV line (1) to the top of the intake manifold.

    17. Object Number: 1887829 Size: SH
  17. Connect the wiring harness electrical connector (3) to the throttle body (4).
  18. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.