GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Optra 🢒 Engine 🢒 Engine Controls and Fuel - 2.0L (Diesel) 🢒 Intake Manifold Replacement

Removal Procedure

    Warning: Refer to Battery Disconnect Warning in the Preface section.


    Object Number: 1863838 Size: SH
  1. Disconnect the negative battery cable.
  2. Remove the engine cover. Refer to Engine Cover Replacement.
  3. Remove the charge air system hoses and ducts. Refer to Charge Air Cooler Inlet Pipe and Outlet Pipe Replacement.

    4. Object Number: 1774275 Size: SH
  4. Disconnect the radiator lower hose and drain coolant. Refer to Cooling System Draining and Filling.

    5. Object Number: 1821742 Size: SH
  5. Remove the accessory belt. Refer to Drive Belt Replacement.

    6. Object Number: 1864038 Size: SH
  6. Remove the fuel pipe-to-injection pump from the fuel injection pump.
  7. Remove the power steering pump fastener and pull it left side.
  8. Remove the coolant hose from intake manifold.
  9. Remove the radiator upper hose.
  10. Remove the injection pump return hose.
  11. Remove the oil level indicator tube.
  12. Remove the fuel pipe-to-common rail between common rail and fuel injection pump. Refer to Fuel Injector Fuel Feed Pipe Replacement.
  13. Remove the engine wiring.
    14. 13.1. Disconnect the common rail pressure sensor connector.
    13.2. Disconnect the CTS connector.
    13.3. Disconnect the injection pump connector.
    13.4. Disconnect the generator connector.
    13.5. Disconnect the A/C compressor connector.
    13.6. Disconnect the starter solenoid wire connector.
    13.7. Disconnect the T-MAP sensor connector
    13.8. Disconnect the CMP sensor connector.
    13.9. Disconnect the ETC body connector.
    13.10. Disconnect the common rail regulator connector.
  14. Remove the engine wiring harness guide.

    15. Object Number: 1820515 Size: SH
  15. Remove the coolant by-pass hose.
  16. Remove the EGR cooler outlet pipe.
  17. Remove the intake manifold with the gasket.

Installation Procedure

    Object Number: 1820515 Size: SH
  1. Install the intake manifold with a new gasket.

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

  2. Install the EGR cooler outlet pipe.

    3. Tighten

        • Tighten the intake manifold bolts and nuts 23 N·m (17 lb ft).
        • Tighten the EGR cooler outlet pipe bolts and nuts 20 N·m (14.8 lb ft).

    Object Number: 1864038 Size: SH
  3. Install the engine wiring.
  4. Install the fuel pipe-to-common rail between common rail and fuel injection pump. Refer to Fuel Injector Fuel Feed Pipe Replacement.
  5. Install the oil level indicator tube.
  6. Install the power steering pump.
  7. Install the fuel pipe-to-injection pump to the fuel injection pump.

    8. Tighten

        • Tighten the glow plug fuse box bolts to 10 N·m (88.5 lb in).
        • Tighten the engine wiring splice pack tightening bolt to 15 N·m (11.1 lb ft).
        • Tighten the fuel pipe-to-common rail to 20 N·m (14.8 lb ft).
        • Tighten the fuel pipe-to-common rail retaining bolt to 10 N·m (88.5 lb in).
        • Tighten the oil level indicator tube bolts to 11 N·m (97.4 lb in).
        • Tighten the power steering pump bolts to 25 N·m (18.4 lb ft).
        • Tighten the fuel pipe-to-injection pump retaining bolt (to intake manifold) to 9 N·m (79.7 lb in).
        • Tighten the fuel pipe-to-injection pump retaining bolt to 25 N·m (18.4 lb ft).