GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1996 🢒 Cavalier 🢒 Engine 🢒 Engine Mechanical - 2.4L 🢒 Intake Manifold Replacement

Removal Procedure
  1. 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.

    in General Information.
  2. Disconnect the following electrical connectors:
    3. • MAP sensor
    • Intake Air Temperature (IAT) sensor
    • EVAP Canister Purge solenoid
    • Fuel injector harness
  3. Disconnect the vacuum hoses from the fuel regulator and the EVAP Canister Purge solenoid to the canister.
  4. Remove the air cleaner duct.
  5. Remove the accelerator control cable bracket.

    6. Object Number: 60047 Size: SH
  6. Remove the stud ended generator mount bolt.

    7. Object Number: 33605 Size: SH
  7. Remove the EGR pipe from the EGR adapter.
  8. Raise and support the vehicle. Refer to SECTION 0A.

    9. Object Number: 60108 Size: SH
  9. Remove the intake manifold support brace.
  10. Lower the vehicle.

    11. Object Number: 33607 Size: SH
  11. Remove the intake manifold retaining nuts and bolts.
  12. Remove the intake manifold and the gasket.

Installation Procedure

    Important: The engine and the manifold should be at ambient temperature when assembled. Do not attempt to install a cold manifold on a hot engine.


    Object Number: 33607 Size: SH
  1. Install the intake manifold and the gasket. If the gasket is damaged, install a new one with the stamped numbers facing towards the manifold surface.

    2. Object Number: 60043 Size: SH
  2. Install the intake manifold fasteners.

    3. Tighten
    Tighten the fasteners to 24 N·m (18 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.

  3. Raise and suitably support the vehicle. Refer to SECTION 0A.

    4. Object Number: 60108 Size: SH
  4. Install the intake manifold brace. Finger start all bolts.

    5. Tighten

        • Tighten bolt (A) to 24 N·m (18 lb ft).
        • Tighten bolt (B) to 26 N·m (19 lb ft).
  5. Lower the vehicle.

    6. Object Number: 33605 Size: SH
  6. Connect the EGR pipe to the EGR adapter.
  7. Install the EGR pipe to the EGR adapter fasteners.

    8. Tighten
    Tighten the fasteners to 26 N·m (19 lb ft).


    Object Number: 60047 Size: SH
  8. Install the stud ended generator mount bolt.
  9. Install the accelerator control cable bracket.
  10. Connect the vacuum hoses to the fuel regulator and to the EVAP canister purge solenoid.

    11. Important: If the Intake Air Temperature (IAT) sensor is removed, apply sealant GM P/N 1052080 or equivalent to its threads before installation.

  11. Connect the following electrical connections:
    12. • MAP sensor
    • IAT sensor
    • EVAP canister purge solenoid
    • Fuel injector harness
  12. Install the air cleaner duct.
  13. Connect the negative battery cable.