GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2008 🢒 Malibu Classic 🢒 Engine 🢒 Engine Mechanical - 2.2L (L61) 🢒 Intake Manifold Replacement

Removal Procedure

    Object Number: 1773469 Size: SH
  1. Remove the throttle body. Refer to Throttle Body Assembly Replacement .
  2. Remove the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement .
  3. Remove the evaporative emission (EVAP) canister purge solenoid valve tube. Refer to Plastic Collar Quick Connect Fitting Service .

    4. Object Number: 1571772 Size: SH
  4. Reposition the brake booster vacuum hose clamp at the intake manifold.
  5. Remove the brake booster hose from the intake manifold.

    6. Object Number: 1773491 Size: SH
  6. Disconnect the engine wiring harness electrical connector from the fuel injector inline electrical connector (2).
  7. Remove the fuel injector inline connector clip (1) from the intake manifold.

    8. Object Number: 1773366 Size: SH
  8. Remove the oil level indicator tube bolt.

    9. Object Number: 1773350 Size: SH
  9. Remove the knock sensor electrical connector clip (3) from the oil level indicator tube.
  10. Reposition the oil level indicator tube as needed.

    11. Object Number: 1773489 Size: SH
  11. Remove the engine wiring harness clips (1) from the intake manifold.

    12. Object Number: 1773474 Size: SH
  12. Remove the intake manifold lower bolts.

    13. Object Number: 1773480 Size: SH
  13. Remove the intake manifold upper bolt and nuts.
  14. Remove the intake manifold.
  15. If replacing the intake manifold proceed to the Installation Procedure.

    16. Important: The intake manifold gasket is reusable, only replace the gasket if damage has occurred.

  16. If reusing the intake manifold perform the following, Inspect the intake manifold gasket for damaged, replace the gasket if necessary.

Installation Procedure

    Object Number: 1773480 Size: SH
  1. Install the NEW gasket to the intake manifold, if necessary.
  2. Install the intake manifold onto the studs.
  3. Install the intake manifold upper bolt and nuts.

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


    Object Number: 1773474 Size: SH
  4. Install the intake manifold lower bolts.

    5. Tighten
    Tighten the bolts/nuts to 10 N·m (89 lb in).


    Object Number: 1773489 Size: SH
  5. Install the engine wiring harness clips (1) to the intake manifold.

    6. Object Number: 1773350 Size: SH
  6. Position the oil level indicator tube as needed.
  7. Install the knock sensor electrical connector clip (3) to the oil level indicator tube.

    8. Object Number: 1773366 Size: SH
  8. Install the oil level indicator tube bolt.

    9. Tighten
    Tighten the bolt to 10 N·m (89 lb in).


    Object Number: 1773491 Size: SH
  9. Connect the engine wiring harness electrical connector to the fuel injector inline electrical connector (2).
  10. Install the fuel injector inline connector clip (1) to the intake manifold.

    11. Object Number: 1571772 Size: SH
  11. Install the brake booster hose to the intake manifold.
  12. Position the brake booster vacuum hose clamp at the intake manifold.

    13. Object Number: 1773469 Size: SH
  13. Install the EVAP canister purge solenoid valve tube. Refer to Plastic Collar Quick Connect Fitting Service .
  14. Install the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement .
  15. Install the throttle body. Refer to Throttle Body Assembly Replacement .