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For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1996 🢒 Cavalier 🢒 Engine 🢒 Engine Mechanical - 2.2L 🢒 Intake Manifold Replacement

Intake Manifold Replacement Upper

Removal Procedure
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
  2. Disconnect the negative battery cable. Refer to

    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.

    .
  3. Remove the air cleaner inlet duct.
  4. Disconnect the vacuum lines as necessary.
  5. Remove the accelerator cable splash shield.

    6. Object Number: 1953 Size: SH
  6. Remove the accelerator bracket.
  7. Remove the following cables:
    8. • The accelerator
    • The cruise control
    • The transmission control
  8. Remove the vacuum hose harness from the top of the air inlet.
  9. Remove the PCV and the brake vacuum hoses at the upper intake manifold.
  10. Disconnect the following connectors:
    11. • The MAP
    • The TP
    • The IAC

    Object Number: 1952 Size: SH
  11. Remove the MAP sensor.

    12. Object Number: 1954 Size: SH
  12. Remove the upper intake manifold assembly bolts.
  13. Remove the upper intake manifold assembly.
  14. Inspect the manifold for cracks and gasket surface damage.

Installation Procedure

    Object Number: 1954 Size: SH
  1. Install the upper intake manifold assembly.

    2. Object Number: 9372 Size: SH
  2. Install the upper intake manifold assembly bolts.

    3. Tighten
    Tighten the bolts to 30 N·m (22 lb ft).

    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.


    Object Number: 1952 Size: SH
  3. Install the MAP sensor.

    4. Tighten
    Tighten the sensor bolts to 3 N·m (27 lb in).


    Object Number: 1953 Size: SH
  4. Install the two bolts and the nut attaching the accelerator cable bracket.
  5. Install the following electrical connections:
    6. • The MAP sensor
    • The IAC
    • The Throttle Position sensor
  6. Connect the PCV and brake vacuum hoses to the upper intake manifold.
  7. Install the vacuum hose harness to the top of the air inlet.
  8. Connect the following cables:
    9. • The accelerator
    • The cruise control
    • The transmission control
  9. Install the accelerator cable splash shield.
  10. Install the accelerator cable splash shield bolts.

    11. Tighten
    Tighten the bolts to 25 N·m (18 lb in).

  11. Install the air cleaner inlet duct.
  12. Connect the negative battery cable.

Intake Manifold Replacement Lower

Removal Procedure
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
  2. Disconnect the negative battery cable. Refer to

    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.

    .
  3. Remove the air cleaner inlet duct.
  4. Remove the accelerator cable splash shield.
  5. Remove the following cables:
    6. • The accelerator
    • The cruise control
    • The TV control
  6. Remove the vacuum hose harness from top of air inlet.
  7. Disconnect the PCV and brake vacuum hoses at the upper intake manifold.

    8. Object Number: 12937 Size: SH
  8. Remove the following electrical connectors:
    9. • The MAP
    • The TP sensor
    • The IAC

    Object Number: 1953 Size: SH
  9. Remove the two bolts and one nut attaching the accelerator bracket.

    10. Object Number: 1952 Size: SH
  10. Remove the MAP sensor.
  11. Remove the upper intake manifold. Refer to Intake Manifold Replacement .
  12. Remove the fuel feed.
  13. Return the quick-connect fittings.
  14. Remove the one bolt holding the intake brace to the power steering pump brace.
  15. Remove the fuel inlet pipe retainers.
  16. Remove the fill tube attaching nut.

    17. Object Number: 3437 Size: SH
  17. Remove the lower intake manifold attaching nuts.
  18. Remove the upper studs on the lower intake manifold.
  19. Remove the lower intake manifold from the engine.
  20. Clean the mating surfaces on the intake manifold and the cylinder head.
  21. Clean excessive carbon deposits from the EGR passage.
  22. Inspect the manifold for cracks, broken flanges, and gasket surface damage.

Installation Procedure

    Object Number: 3437 Size: SH
  1. Install a new lower intake manifold gasket.
  2. Install the lower intake manifold assembly.
  3. Install the lower intake manifold to cylinder head studs.

    4. Tighten
    Tighten the studs to 10 N·m (89 lb in).

    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.


    Object Number: 3435 Size: SH
  4. Install the lower intake manifold to cylinder head nuts.

    5. Tighten
    Tighten the nuts to 33 N·m (24 lb ft).

  5. Install the transmission fill tube attaching nut.
  6. Install the fuel inlet pipe retainers.

    7. Tighten
    Tighten the bolts to 25 N·m (18 lb in).

  7. Install the bolt holding the intake brace to the power steering pump brace.

    8. Object Number: 9949 Size: SH
  8. Connect the fuel feed and return quick-connect fittings.
  9. Install the upper intake manifold. Refer to Intake Manifold Replacement .

    10. Object Number: 1952 Size: SH
  10. Install the MAP sensor.
  11. Install the MAP sensor bolt.

    12. Tighten
    Tighten the bolt to 3 N·m (27 lb in).


    Object Number: 1953 Size: SH
  12. Install the two bolts and one nut attaching the accelerator cable bracket.

    13. Object Number: 12937 Size: SH
  13. Connect the following electrical connectors:
    14. • The MAP
    • The TP sensor
    • The IAC
  14. Connect the PCV and brake vacuum hoses at the upper intake manifold.
  15. Install the vacuum hose harness from the top of the air inlet.
  16. Connect the following cables:
    17. • The accelerator
    • The cruise control
    • The transmission control
  17. Install the accelerator cable splash shield.
  18. Install the accelerator cable splash shield screws.

    19. Tighten
    Tighten the screws to 25 N·m (18 lb in).

  19. Install the air inlet duct assembly.
  20. Install the fuel pump fuse. Check the fuel pump fuse for leaks.
  21. Connect the negative battery cable.