GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1999 🢒 Malibu 🢒 Engine 🢒 Engine Mechanical - 2.4L 🢒 Intake Manifold Replacement

Removal Procedure

    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.

  1. Disconnect the negative battery cable.
  2. Remove the air cleaner duct.
  3. Disconnect the following electrical connectors:
    4. • Manifold absolute pressure (MAP) sensor
    • Intake air temperature (IAT) sensor
    • Evaporative emissions (EVAP) canister purge solenoid
    • Fuel injector harness
  4. Disconnect the vacuum hoses from the fuel regulator and the EVAP canister purge solenoid to the canister.
  5. Remove the accelerator control cable bracket.

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

    7. Object Number: 387645 Size: SH
  7. Remove the intake manifold retaining nuts and bolts.
  8. 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: 387645 Size: SH
  1. Install the intake manifold and the gasket. If damaged, install a new gasket with the stamped numbers facing towards the manifold surface.

    2. Object Number: 60043 Size: SH

    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.

  2. Install the intake manifold fasteners in the sequence shown.

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

  3. Install the EGR pipe to the EGR adapter fasteners.

    4. Object Number: 60047 Size: SH
  4. Install the stud-end generator mount bolt.
  5. Install the accelerator control cable bracket.
  6. Connect the vacuum hoses to the fuel regulator and to the EVAP canister purge solenoid.

    7. Important: If you have removed the intake air temperature (IAT) sensor, apply sealant GM P/N 1052080 or equivalent to the threads before installation.

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