GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Optra 🢒 Preface 🢒 Dangers, Warnings, and Cautions 🢒 Intake Manifold Replacement

Removal Procedure

    Object Number: 1291147 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. Warning: Refer to Battery Disconnect Warning in the Preface section.

  3. Disconnect the negative battery cable.
  4. Disconnect the engine control module (ECM) ground terminal from the intake manifold.

    5. Warning: Refer to Safety Glasses Warning in the Preface section.

  5. Drain the engine coolant. Refer to Cooling System Draining and Filling.

    6. Object Number: 1291138 Size: SH
  6. Remove the engine cover and throttle body. Refer to Throttle Body Assembly Replacement.

    7. Object Number: 1291148 Size: SH
  7. Disconnect the intake manifold pressure sensor connector, attaching bolt, and vacuum hose.

    8. Object Number: 1291151 Size: SH
  8. Disconnect the intake air temperature (IAT) sensor connector and remove the IAT sensor.

    9. Object Number: 1291152 Size: SH
  9. Remove the intake manifold upper bracket
  10. Remove the fuel rail bolts and the fuel rail.

    11. Object Number: 1291153 Size: SH
  11. Remove the all the vacuum hoses from the intake manifold including the positive crankcase ventilation (PCV) hose and brake booster vacuum hose.
  12. Remove the exhaust gas recirculation (EGR) pipe.

    13. Object Number: 1510545 Size: SH
  13. Remove the intake manifold upper bracket bolts.
  14. Remove the intake manifold upper bracket.
  15. Remove the fuel rail bolts.
  16. Remove the fuel rail.

    17. Object Number: 1291155 Size: SH
  17. Remove the alternator. Refer to Generator Replacement l.
  18. Remove the intake manifold support bracket.

    19. Object Number: 1291157 Size: SH
  19. Remove the intake manifold retaining bolts/nuts in the sequence shown.
  20. Remove the intake manifold and gasket.
  21. Clean the sealing surfaces of the intake manifold and the cylinder head.

Installation Procedure

    Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 1291167 Size: SH
  1. Install the fuel rail.

    2. Tighten
    Tighten the fuel rail bolts to 25 N·m (18 lb ft).

  2. Install the new intake manifold gasket and intake manifold.

    3. Tighten
    Tighten the intake manifold bolts and nuts to 25 N·m (18 lb ft).


    Object Number: 1291180 Size: SH
  3. Install the EGR pipe.

    4. Tighten
    Tighten the EGR pipe bolts to 10 N·m (89 lb ft).


    Object Number: 1291191 Size: SH
  4. Install the intake manifold support bracket.

    5. Tighten

        • Tighten the intake manifold support bracket upper bolts to 25 N·m (18 lb ft).
        • Tighten the lower bolts to 45 N·m (33 lb ft).
  5. Install the alternator. Refer to Generator Replacement.

    6. Object Number: 1510545 Size: SH
  6. Install the fuel rail.
  7. Install the fuel rail bolts.

    8. Tighten
    Tighten the fuel rail bolts to 25 N·m (18 lb ft).

  8. Install the intake manifold upper bracket.
  9. Install the intake manifold upper bracket bolts.

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


    Object Number: 1291151 Size: SH
  10. Install the IAT and connect the IAT sensor connector.

    11. Object Number: 1291148 Size: SH
  11. Install the intake manifold pressure sensor and vacuum hose.

    12. Object Number: 1291138 Size: SH
  12. Install the throttle body and engine cover. Refer to Throttle Body Assembly Replacement
  13. Refill the engine cooling system. Refer to Cooling System Draining and Filling.
  14. Install the fuel pump fuse and connect the negative battery cable.