GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Epica 🢒 Engine 🢒 Engine Mechanical - 2.0L (L34 GMDAT) 🢒 Intake Manifold Replacement

Removal Procedure

    Object Number: 1252114 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. Disconnect the canister purge solenoid from the intake manifold and loosen the bracket bolt.
  5. Drain the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.

    6. Object Number: 1252116 Size: SH
  6. Disconnect the manifold air temperature sensor connector.
  7. Disconnect the air intake tube from the throttle body.

    8. Object Number: 1252117 Size: SH
  8. Disconnect the idle air control (IAC) valve connector.
  9. Disconnect the throttle position (TP) sensor connector.
  10. Disconnect the manifold absolute pressure (MAP) sensor connector.
  11. Disconnect the coolant hose at the throttle body.

    12. Object Number: 1248341 Size: SH
  12. Disconnect all of the necessary vacuum hoses, including the vacuum hose at the fuel pressure regulator and the brake booster vacuum hose at the intake manifold.
  13. Disconnect the throttle cable from the throttle body and the intake manifold.
  14. Remove the throttle cable bracket bolts from the intake manifold.
  15. Remove the throttle cable bracket.
  16. Remove the alternator-to-intake manifold strap bracket bolts and the strap.
  17. Remove the power steering hose clamp bolt, and position the hose clear of the repair area.

    18. Object Number: 1252127 Size: SH
  18. Remove the fuel rail and the injector cover. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls-2.0 L.
  19. Remove the alternator-to-intake manifold support bracket bolts.
  20. Remove the alternator-to-intake manifold support bracket.
  21. Remove the intake manifold support bracket bolt at the engine block and the intake manifold.
  22. Remove the intake manifold support bracket.

    23. Object Number: 1252157 Size: SH
  23. Remove the intake manifold retaining bolts and the nuts in the sequence shown.
  24. Remove the intake manifold.
  25. Remove the intake manifold gasket.

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

  26. Clean the sealing surfaces of the intake manifold and the cylinder head.

Installation Procedure

    Object Number: 1252158 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 bolts and the nuts in the sequence shown.

    4. Tighten
    Tighten the intake manifold retaining bolts and the nuts to 22 N·m (16 lb ft).

  4. Install the alternator-to-intake manifold strap bracket and bolts.

    5. Tighten
    Tighten the alternator-to-intake manifold strap bracket bolts to 20 N·m (15 lb ft).


    Object Number: 1252159 Size: SH
  5. Install the intake manifold support bracket.
  6. Install the intake manifold support bracket upper bolts to the intake manifold.

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

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

    8. Tighten
    Tighten the intake manifold support bracket lower bolt to the engine block to 25 N·m (18 lb ft).

  8. Install the alternator-to-intake manifold support bracket bolts.

    9. Tighten
    Tighten the alternator-to-intake manifold support bracket and bolts to 35 N·m (26 lb ft).


    Object Number: 1252161 Size: SH
  9. Install the fuel rail and the injector cover. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls-2.0 L.
  10. Install the throttle cable bracket.
  11. Install the throttle cable bracket bolts.

    12. Tighten
    Tighten the throttle cable bracket bolts to 8 N·m (71 lb in).

  12. Connect the throttle cable to the intake manifold and the throttle body.
  13. Connect all of the necessary vacuum lines that were previously disconnected.

    14. Object Number: 1252117 Size: SH
  14. Connect the MAP sensor connector.
  15. Connect the coolant hoses to the throttle body.
  16. Connect the IAC connector.
  17. Connect the TP sensor connector.
  18. Position the power steering hose in place and install the clamp bolt.

    19. Tighten
    Tighten the power steering hose clamp bolt to 8 N·m (71 lb in).


    Object Number: 1252116 Size: SH
  19. Connect the air intake tube to the throttle body.
  20. Connect the manifold air temperature sensor connector.
  21. Connect the canister purge solenoid at the intake manifold and tighten the bracket bolt.

    22. Tighten
    Tighten the canister purge solenoid bracket bolt to 5 N·m (44 lb in).

  22. Install the fuel pump fuse.
  23. Connect the negative battery cable.
  24. Refill the engine cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.