GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2001 🢒 Prizm 🢒 Engine 🢒 Engine Mechanical - 1.8L 🢒 Intake Manifold Replacement

Removal Procedures

    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. Drain the cooling system.

    3. Refer to Cooling System Draining and Filling in Engine Cooling.

  3. Disconnect the accelerator cable from the throttle body. Refer to Accelerator Control Cable Replacement in Engine Controls - 1.8 L.
  4. Disconnect the Throttle Valve (TV) cable (automatic transmission). Refer to Automatic Transmission Throttle Valve Cable Replacement in Automatic Transmission.

    5. Object Number: 236882 Size: SH
  5. Disconnect the IAT sensor connector at the air cleaner.
  6. Disconnect the air cleaner hose from the throttle body (1).
  7. Remove the air cleaner top assembly.
  8. Disconnect the following components from the throttle body:
    9. • The throttle position (TP) sensor connector
    • The idle air control (IAC) valve connector
    • The manifold absolute pressure (MAP) sensor connector
    • Two coolant bypass hose clamps
    • The coolant bypass hoses

    Object Number: 234436 Size: SH
  9. Disconnect the four fuel injector connectors at the injectors.
  10. Remove the three bolts from the fuel injector wiring harness (3, 4).
  11. Disconnect the wiring harness from the intake manifold.

    12. Object Number: 234438 Size: SH
  12. Remove the following components:
    13. • The intake manifold support bracket bolts (7)
    • The intake manifold support bracket

    Object Number: 233533 Size: SH
  13. Disconnect the upper radiator hose at the radiator.

    14. Move the hose to the side.

  14. Remove the following fasteners:
    15. • The upper radiator hose support bracket bolt
    • The nut

    Object Number: 234438 Size: SH
  15. Remove the following components from the cylinder head:
    16. • The intake manifold bolts (2)
    • The nut (1)
  16. Remove the upper radiator hose support bracket.
  17. Disconnect the three vacuum lines at the intake manifold.
  18. Remove the two injector harness support brackets.
  19. Remove the intake manifold with the throttle body from the cylinder head.

Installation Procedure

    Object Number: 234438 Size: SH
  1. Install the following components to the cylinder head:
    2. • A new intake manifold gasket
    • The intake manifold with the throttle body

    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. Use the following components in order to secure the manifold:
    3. • Three nuts (2)
    • Two bolts (1)

    Tighten
    Tighten the intake manifold nuts and the bolts to 18 N·m (13 lb ft).

  3. Install the two injector harness support brackets.
  4. Connect the three vacuum lines at the intake manifold.

    5. Object Number: 233533 Size: SH
  5. Install the upper radiator hose support bracket.
  6. Connect the upper radiator hose to the radiator.

    7. Object Number: 234438 Size: SH
  7. Install the intake manifold support bracket. Secure the bracket using two bolts (7).

    8. Tighten
    Tighten the intake manifold support bracket bolts to 18 N·m (13 lb ft).


    Object Number: 234436 Size: SH
  8. Install the fuel injector wiring harness. Secure the harness using three bolts (3, 4).

    9. Tighten
    Tighten the bolts to 12.7 N·m (9 lb ft).

  9. Connect the four fuel injector connectors to the fuel injectors.

    10. Object Number: 236882 Size: SH
  10. Connect the following components to the throttle body:
    11. • The throttle position (TP) sensor connector
    • The idle air control (IAC) valve connector
    • The manifold absolute pressure (MAP) sensor connector
    • The two coolant bypass hose clamps
    • The coolant bypass hoses
  11. Install the air cleaner top assembly.
  12. Connect the air cleaner hose (1) to the throttle body.
  13. Connect the intake air temperature (IAT) sensor connector to the air cleaner.

    14. Object Number: 234418 Size: SH
  14. Install the throttle valve (TV) cable (automatic transmission). Refer to Automatic Transmission Throttle Valve Cable Replacement in Automatic Transmission.
  15. Install the accelerator cable to the throttle body (1). Refer to Accelerator Control Cable Replacement in Engine Controls - 1.8 L..
  16. Refill the cooling system as necessary. Refer to Cooling System Draining and Filling in Engine Cooling.
  17. Connect the negative battery cable.

    18. Tighten
    Tighten the battery cable bolt to 15 N·m (11 lb ft).