GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 HHR 🢒 Engine 🢒 Engine Cooling 🢒 Intake Manifold Replacement

Removal Procedure

    Object Number: 1623764 Size: SH
  1. Remove the throttle body. Refer to Throttle Body Assembly Replacement .
  2. Disconnect the fuel injector electrical connector (2).

    3. Object Number: 1627740 Size: SH
  3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
  4. Disconnect the engine harness clips (2 and 4) from the intake manifold.
  5. Lower the vehicle.
  6. Remove the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement .
  7. Disconnect the fuel injector electrical connector clip (3) from the intake manifold.

    8. Object Number: 1628035 Size: SH
  8. Reposition the vacuum brake booster hose clamp at the intake manifold.
  9. Remove the vacuum brake booster hose from the intake manifold.

    10. Object Number: 1623766 Size: SH
  10. Disconnect the evaporative emission (EVAP) canister purge tube from the intake manifold and the EVAP solenoid. Refer to Plastic Collar Quick Connect Fitting Service .
  11. Remove the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement .

    12. Object Number: 1623769 Size: SH
  12. Remove the intake manifold lower bolts.

    13. Object Number: 1571773 Size: SH
  13. Remove the intake manifold upper bolt and nuts.
  14. Remove the intake manifold.

    15. Note: The intake manifold O-ring seals are reusable, only replace the seals if damage has occurred.

  15. Inspect the intake manifold O-ring seals.

Installation Procedure

    Object Number: 1571773 Size: SH
  1. Install NEW intake manifold O-ring seals if necessary.
  2. Install the intake manifold.
  3. Install the intake manifold upper bolt and nuts.

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


    Object Number: 1623769 Size: SH
  4. Install the intake manifold lower bolts (1). Tighten the bolts/nuts to 10 N·m (89 lb in) .

    5. Object Number: 1623766 Size: SH
  5. Install the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement .
  6. Connect the EVAP canister purge tube to the intake manifold and the EVAP solenoid. Refer to Plastic Collar Quick Connect Fitting Service .

    7. Object Number: 1628035 Size: SH
  7. Install the vacuum brake booster hose to the intake manifold.
  8. Position the vacuum brake booster hose clamp at the intake manifold.

    9. Object Number: 1627740 Size: SH
  9. Connect the fuel injector electrical connector clip (3) to the intake manifold.
  10. Install the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement .
  11. Raise and support the vehicle.
  12. Connect the engine harness clips (2 and 4) to the intake manifold.
  13. Lower the vehicle.

    14. Object Number: 1623764 Size: SH
  14. Connect the fuel injector electrical connector (2).
  15. Install the throttle body. Refer to Throttle Body Assembly Replacement .