GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Corvette 🢒 HVAC 🢒 Heating, Ventilation, and Air Conditioning 🢒 Intake Manifold Replacement

Removal Procedure

    Object Number: 1464324 Size: SH

    Note: The intake manifold, throttle body, fuel injection rail, and injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.

  1. Remove the engine sight covers (2, 3). Refer to Upper Intake Manifold Sight Shield Replacement.

    2. Object Number: 651871 Size: SH
  2. Disconnect the electrical connector (1) for the fuel injectors.
  3. Disconnect the electrical connectors (3) from the throttle body.
  4. Disconnect the fuel feed for the fuel injectors.

    5. Object Number: 63936 Size: SH
  5. Remove the vacuum hose from the brake booster.
  6. Disconnect the electrical connector from the manifold absolute pressure (MAP) sensor.

    7. Object Number: 1408858 Size: SH
  7. Remove the MAP sensor (714).
  8. Remove the grommet (715) from the sensor, as required.

    9. Object Number: 1408859 Size: SH
  9. Remove the evaporative emission (EVAP) clip (740), bolt (742), bracket (741), valve (730), and tubes (729, 735).

    10. Object Number: 1408860 Size: SH
  10. Remove the intake manifold bolts (512) and fuel rail stop bracket (712).
  11. Remove the intake manifold (500).

    12. Object Number: 1272799 Size: SH
  12. Remove the intake manifold gaskets (514).
  13. Discard the intake manifold gaskets.

Installation Procedure

    Object Number: 1272799 Size: SH

    Note: DO NOT reuse the intake manifold gaskets. Install NEW intake manifold gaskets.

    Note: 

       • The intake manifold, throttle body, fuel injection rail and fuel injectors may be removed as an assembly. If not servicing the individual components, install the intake manifold as a complete assembly.
       • DO NOT use the intake manifold gaskets again. Install NEW intake manifold-to-cylinder head gaskets.

  1. Install NEW intake manifold-to-cylinder head gaskets (514).

    2. Object Number: 1408860 Size: SH
  2. Install the intake manifold (500).
  3. Apply a 5 mm (0.20 in) band of threadlocker to the threads of the intake manifold bolts (512). Refer to Adhesives, Fluids, Lubricants, and Sealers for the correct part number.
  4. Install the fuel rail stop bracket (712).
  5. Install the intake manifold bolts (512).

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


    Object Number: 63222 Size: SH
  6. Tighten the intake manifold bolts to the sequence below:

    7. Tighten

        • First Pass: Tighten the intake manifold bolts in sequence to 5 N·m (44 lb in).
        • Final Pass: Tighten the intake manifold bolts in sequence to 10 N·m (89 lb in).

    Object Number: 1408858 Size: SH
  7. Lubricate the MAP sensor grommet (715) with clean engine oil.
  8. Install the MAP sensor (714) and grommet (715).

    9. Object Number: 1408859 Size: SH
  9. Install the EVAP valve (730), bracket (741), and bolt (742).

    10. Tighten
    Tighten the bolt to 50 N·m (37 lb ft).

  10. Install the EVAP tubes (729, 735).
  11. Install the fuel rail. Refer to Fuel Rail and Injectors Installation.
  12. Reconnect the electrical connector for the MAP sensor.

    13. Object Number: 63936 Size: SH
  13. Install the vacuum hose for the brake booster.

    14. Object Number: 651871 Size: SH
  14. Reconnect the electrical connectors (3) throttle body.
  15. Reconnect the electrical connector (1) for the fuel injectors.
  16. Refill the cooling system. Refer to Cooling System Draining and Filling.

    17. Object Number: 1464324 Size: SH
  17. Install the engine sight covers (2, 3). Refer to Upper Intake Manifold Sight Shield Replacement.