GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 S10 Pickup - 2WD 🢒 Engine 🢒 Engine Mechanical - 2.2L 🢒 Intake Manifold Replacement

Removal Procedure

    Object Number: 346145 Size: SH
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Remove the upper fan shroud. Refer to Fan Shroud Replacement in Engine Cooling.
  3. Disconnect the power brake booster vacuum hose.
  4. Remove the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator Replacement in Engine Controls - 2.2L (LN2).

    5. Object Number: 565578 Size: SH
  5. Disconnect the following electrical connectors:
    6. • Idle air control (IAC) motor (1)
    • Manifold absolute pressure (MAP) sensor (4)
    • Throttle position (TP) sensor (2)
    • Engine coolant temperature (ECT) sensor (3)

    Object Number: 565513 Size: SH
  6. Disconnect the fuel injector harness electrical connector.
  7. Remove the fuel injector harness electrical connector from the bracket on the valve rocker arm cover.
  8. Remove the engine wiring harness from the bracket.
  9. Move and secure the engine wiring harness out of the way.

    10. Object Number: 565819 Size: SH
  10. Disconnect the heating and air conditioning control vacuum source hose.
  11. Disconnect the EVAP emission purge tube from the throttle body.

    12. Object Number: 566052 Size: SH
  12. Remove the bolt holding the EVAP emission canister purge harness and if equipped the transmission fluid fill tube.
  13. Remove the nut holding the engine wiring harness clip to the intake manifold.
  14. Remove the nut holding the engine wiring harness clip to the intake manifold rear lower stud.
  15. Disconnect the fuel hose from the fuel rail. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls - 2.2L (LN2).
  16. Remove the accelerator control cable from the throttle body. Refer to Accelerator Pedal Replacement in Engine Controls - 2.2L (LN2).
  17. Remove the cruise control cable from the throttle body. Refer to Cruise Control Cable Replacement in Cruise Control.

    18. Object Number: 382647 Size: SH
  18. Remove the spark plug wires from the spark plugs. Refer to Spark Plug Wire Replacement in Engine Controls - 2.2L (LN2).
  19. Remove the spark plug wire harness retainer from the thermostat assembly and set aside the spark plug wire harness.

    20. Object Number: 303008 Size: SH
  20. Remove the right fender wheelhouse extension.

    21. Object Number: 43037 Size: SH
  21. Working through the wheelhouse, remove the generator rear brace from the engine.
    22. • Remove the nuts holding the brace to the intake stud and the engine block.
    • Remove the bolt holding the brace to the rear of the generator.

    Object Number: 349613 Size: SH
  22. Remove the engine wiring harness bracket at the back of the engine using the following procedure:
    23. 22.1. Loosen the bolt at the rear of the cylinder head.
    22.2. Remove the 2 bolts that secure the bracket to the valve rocker arm cover.
    22.3. Slide the bracket off of the bolt at the rear of the cylinder head.

    Object Number: 182948 Size: SH
  23. Remove the intake manifold bolts.
  24. Remove the intake manifold nuts.
  25. Remove the fuel rail bracket.
  26. Remove the intake manifold.
  27. If replacing the intake manifold remove the following:
    28. • The throttle body
    •  Refer to Throttle Body Assembly Replacement in Engine Controls - 2.2L (LN2).
    • The fuel rail
    • Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls - 2.2L (LN2).
  28. Clean the intake manifold mating surfaces.
  29. Inspect the intake manifold for damage.
  30. Inspect the intake manifold for cracks near compression limiters.
  31. Inspect the crankcase ventilation passages in the intake manifold face for blockage and clean as necessary.
  32. Replace the intake manifold as necessary.

Installation Procedure
  1. Install the fuel rail if removed. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls - 2.2L (LN2).
  2. Install the throttle body if removed. Refer to Throttle Body Assembly Replacement in Engine Controls - 2.2L (LN2).

    3. Object Number: 182948 Size: SH
  3. Install the intake manifold gasket.
  4. Install the intake manifold.

    5. Object Number: 212752 Size: SH

    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.

  5. Install the intake manifold bolts.

    6. Tighten
    Tighten the bolts in sequence to 24 N·m (17 lb ft).


    Object Number: 349613 Size: SH
  6. Install the engine wire harness bracket to the rear of the engine using the following procedure:
    7. 6.1. Slide the bracket over the bolt at the rear of the cylinder head.
    6.2. Install the 2 bolts that secure the bracket to the valve rocker arm cover.
  7. Tighten the bolts in the following order:

    8. Tighten

    1. Tighten the 2 bolts to the valve rocker arm cover to 10 N·m (89 lb in).
    2. Tighten the bolt at the rear of the cylinder head to 25 N·m (18 lb ft).

    Object Number: 43037 Size: SH
  8. Working through the wheelhouse, install the generator rear brace.
  9. Install the nuts holding the brace to the intake manifold stud and the stud on the engine.
  10. Install the bolt holding the brace to the rear of the generator.

    11. Tighten
    Tighten the generator rear brace nuts and bolts to 25 N·m (18 lb ft).


    Object Number: 382647 Size: SH
  11. Position the spark plug wire harness.
  12. Install the spark plug wire harness retainer on the thermostat assembly.
  13. Install the spark plug wires to the spark plugs. Refer to Spark Plug Wire Replacement in Engine Controls - 2.2L (LN2).
  14. Install the accelerator control cable to the throttle body. Refer to Accelerator Pedal Replacement in Engine Controls - 2.2L (LN2).
  15. Install the cruise control cable to the throttle body. Refer to Cruise Control Cable Replacement in Cruise Control.
  16. Connect the fuel hose to the fuel rail. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls - 2.2L (LN2).

    17. Object Number: 566052 Size: SH
  17. Install the bolt holding the EVAP emission canister purge harness and if equipped the transmission fluid fill tube.

    18. Tighten
    Tighten the bolts to 10 N·m (89 lb in).

  18. Install the nut holding the engine wiring harness clip and the negative battery cable clip to the intake manifold.

    19. Tighten
    Tighten the engine wiring harness clip nut to 10 N·m (89 lb in).

  19. Install the nut holding the engine wiring harness clip to the intake manifold rear lower stud.

    20. Tighten
    Tighten the engine wiring harness clip nut to 30 N·m (89 lb in).


    Object Number: 565819 Size: SH
  20. Connect the heating and air conditioning control vacuum source hose.
  21. Connect the EVAP emission purge tube to the throttle body.

    22. Object Number: 565513 Size: SH
  22. Position the engine wiring harness.
  23. Install the engine wiring harness to the bracket.
  24. Install the fuel injector harness electrical connector to the bracket on the valve rocker arm cover.
  25. Connect the fuel injector harness electrical connector.

    26. Object Number: 565578 Size: SH
  26. Connect the following electrical connectors:
    27. • Idle air control (IAC) motor (1)
    • Manifold absolute pressure (MAP) sensor (4)
    • Throttle position (TP) sensor (2)
    • Engine coolant temperature (ECT) sensor (3).

    Object Number: 303008 Size: SH
  27. Install the right fender wheelhouse extension.
  28. Install the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator Replacement in Engine Controls - 2.2L (LN2).

    29. Object Number: 346145 Size: SH
  29. Install the upper fan shroud. Refer to Fan Shroud Replacement in Engine Cooling.
  30. Connect the power brake booster vacuum hose.
  31. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.