GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Optra - Mexico 🢒 Diagnostic Navigation 🢒 Vehicle Diagnostic Information 🢒 Intake Manifold Replacement

Removal Procedure

    Object Number: 1289766 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 charcoal canister purge (CCP) and exhaust gas recirculation (EGR) solenoid from the intake manifold and loosen the bracket bolt.
  5. Drain the engine coolant. Refer to Cooling System Draining and Filling.

    6. Object Number: 1289768 Size: SH
  6. Disconnect the intake air temperature sensor (IAT) connector.
  7. Disconnect the air cleaner outlet hose from the throttle body.

    8. Object Number: 1289769 Size: SH
  8. Disconnect the idle air control (IAC) valve connector.
  9. Disconnect the throttle position sensor (TPS) connector.
  10. Disconnect the manifold absolute pressure (MAP) sensor connector.
  11. Disconnect the coolant hoses at the throttle body.

    12. Object Number: 1289835 Size: SH
  12. Disconnect all of the necessary vacuum hoses, including the vacuum hose at the fuel pressure regulator and the brake booster vacuum hose at the intake manifold.
  13. Disconnect the throttle cable from the throttle body and the intake manifold.
  14. Remove the throttle cable bracket bolts from the intake manifold.
  15. Remove the throttle cable bracket.
  16. Remove the generator-to-intake manifold strap bracket bolts and strap.

    17. Object Number: 1289779 Size: SH
  17. Remove the fuel rail as an assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement.
  18. Remove the generator-to-intake manifold support bracket bolts.
  19. Remove the generator-to-intake manifold support bracket.
  20. Remove the intake manifold support bracket bolt at the engine block and the intake manifold.
  21. Remove the intake manifold support bracket.

    22. Object Number: 1289837 Size: SH
  22. Remove the intake manifold retaining bolt and nuts in the sequence shown.
  23. Remove the intake manifold.
  24. Remove the intake manifold gasket.
  25. Clean the sealing surfaces of the intake manifold and the cylinder head.

Installation Procedure

    Object Number: 1289838 Size: SH
  1. Install the intake manifold gasket.
  2. Install the intake manifold.

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

  3. Install the intake manifold retaining bolt and nuts in the sequence shown.

    4. Tighten
    Tighten the intake manifold retaining bolt and nuts to 22 N·m (16 lb ft).

  4. Install the generator-to-intake manifold strap bracket bolts.

    5. Tighten
    Tighten the generator-to-intake manifold strap bracket bolts to 22 N·m (16 lb ft).


    Object Number: 1289779 Size: SH
  5. Install the intake manifold support bracket.
  6. Install the intake manifold support bracket upper bolts to the intake manifold.

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

  7. Install the intake manifold support bracket lower bolt to the engine block.

    8. Tighten
    Tighten the intake manifold support bracket lower bolt to the engine block to 25 N·m (18 lb ft).

  8. Install the generator-to-intake manifold support bracket bolts to 37 N·m (27 lb ft).

    9. Object Number: 1289835 Size: SH
  9. Install the fuel rail and injector cover as an assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement.
  10. Install the throttle cable bracket.
  11. Install the throttle cable bracket bolts.

    12. Tighten
    Tighten the throttle cable bracket bolts to 8 N·m (71 lb in).

  12. Connect the throttle cable to the intake manifold and the throttle body.
  13. Connect all of the necessary vacuum lines that were previously disconnected.

    14. Object Number: 1289769 Size: SH
  14. Connect the MAP sensor connector.
  15. Connect the coolant hoses to the throttle body.
  16. Connect the IAC valve connector.
  17. Connect the TP sensor connector.

    18. Object Number: 1289768 Size: SH
  18. Connect the air cleaner outlet hose to the throttle body.
  19. Connect the IAT sensor connector.
  20. Connect the CCP and EGR solenoid at the intake manifold and tighten the bracket bolt.

    21. Tighten
    Tighten the charcoal canister purge and exhaust gas recirculation solenoid bracket bolt to 5 N·m (44 lb in).

  21. Install the fuel pump fuse.
  22. Connect the negative battery cable.
  23. Refill the engine cooling system. Refer to Cooling System Draining and Filling.