GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2004 🢒 Tracker - 4WD 🢒 Engine 🢒 Engine Cooling 🢒 Intake Manifold Replacement

Removal Procedure
  1. Release fuel pressure in fuel feed. Refer to Fuel Pressure Relief in Engine Controls.

    2. 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.

  2. Disconnect the negative battery cable.
  3. Drain the coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
  4. Remove the Front Suspension support brace. Refer to Front Suspension Support Brace Replacement in Front Suspension.
  5. Remove the 4 screws and the fuel injector sight shield.

    6. Object Number: 648016 Size: SH
  6. Remove the air cleaner upper case, the intake air hose, the intake air pipe (2) and the surge tank pipe (1) as one component.

    7. Object Number: 648013 Size: SH
  7. Disconnect the accelerator cable (2) from the throttle body.
  8. If the vehicle has an automatic transmission disconnect the automatic transmission throttle cable (1) from the throttle body.
  9. Disconnect the water hoses (3) from the throttle body.

    10. Object Number: 648018 Size: SH
  10. Disconnect the injector wire coupler (1).
  11. Disconnect the brake booster hose (2) from the intake manifold.

    12. Object Number: 648017 Size: SH
  12. Disconnect the following electrical connectors:
    13. • The throttle position sensor (TPS) (2)
    • The mass air flow (MAF) sensor (1)
    • The idle air control (IAC) valve (3)
  13. Disconnect the ground terminal (5) from the intake collector.
  14. Remove the clamp bracket (4) from the intake collector.

    15. Object Number: 648002 Size: SH
  15. Disconnect the following electrical connectors:
    16. • The manifold differential pressure (MDP) sensor
    • The EVAP canister purge valve (2)
    • The exhaust gas recirculation (EGR) valve (7)
  16. Disconnect the following hoses:
    17. • The PCV hose from the cylinder head cover (9)
    • The breather hose from the throttle body (6)
    • The EVAP canister purge valve hose (1)
    • The water hose (8)
    • The heater hoses (3,5)
  17. Remove the EGR pipe (4).

    18. Object Number: 647999 Size: SH
  18. Disconnect the following hoses:
    19. • The heater hose (2)
    • The EVAP canister hose (1)
    • The fuel feed hose (4)
    • The fuel return hose (3)
    • The tank pressure control solenoid valve hose

    Object Number: 644083 Size: SH
  19. Disconnect the hose (2) from the idle air control (IAC) valve.
  20. Remove the idle air control (IAC) valve.
  21. Remove the 4 nuts and 2 bolts on the intake collector.

    22. Object Number: 644066 Size: SH
  22. Remove the intake collector (1) and throttle body (2) from the intake manifold (3) as an assembly.

    23. Object Number: 644089 Size: SH
  23. If necessary, remove the 2 nuts and 2 bolts and remove the throttle (2) body from the intake collector (1).

    24. Object Number: 648019 Size: SH
  24. Remove the 8 bolts and 4 nuts on the intake manifold.
  25. Remove the intake manifold.

Installation Procedure

    Object Number: 644091 Size: SH
  1. Install the new intake manifold gaskets (1) onto the cylinder heads.

    2. Object Number: 648019 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.

  2. Install the intake manifold. Secure the intake manifold with the 8 bolts and 4 nuts.

    3. Tighten
    Tighten the bolts and nuts to 23 N·m (16.5 lb ft).


    Object Number: 644089 Size: SH
  3. Install the new throttle body gasket to the intake collector.
  4. Install the throttle body (2) to the intake collector (1). Secure the throttle body with the 2 bolts and 2 nuts.

    5. Tighten
    Tighten the nuts and bolts to 12 N·m (8.5 lb ft).


    Object Number: 644066 Size: SH
  5. Install the intake collector (1) and the throttle body (2) as an assembly to the intake manifold (3) with a new gasket. Secure with the 4 nuts and 2 bolts.

    6. Tighten
    Tighten the nuts and bolts to 12 N·m (8.5 lb ft).


    Object Number: 647999 Size: SH
  6. Install the idle air control (IAC) valve with a new gasket.
  7. Connect the following hoses:
    8. • The heater hose (2)
    • The EVAP canister hose (1)
    • The fuel feed hose (4)
    • The fuel return hose (3)
    • The tank pressure control solenoid valve hose

    Object Number: 648002 Size: SH
  8. Install the exhaust gas recirculation (EGR) pipe (4).
  9. Connect the following hoses:
    10. • The PCV hose to the cylinder head cover (9)
    • The breather hose to the throttle body (6)
    • The EVAP canister purge valve hose (1)
    • The water hose (8)
    • The heater hoses (3,5)
  10. Connect the following electrical connectors:
    11. • The manifold differential pressure (MDP) sensor
    • The EVAP canister purge valve (1)
    • The exhaust gas recirculation (EGR) valve (2)

    Object Number: 648017 Size: SH
  11. Install the clamp bracket (4) to intake collector.
  12. Install the ground terminal (5) to intake collector.
  13. Connect the following electrical connectors:
    14. • The throttle position sensor (TPS) (2)
    • The mass air flow (MAF) sensor (1)
    • The idle air control (IAC) valve (3)

    Object Number: 648018 Size: SH
  14. Connect the brake booster hose (2) to the intake manifold.
  15. Connect the injector wire coupler (1).

    16. Object Number: 648013 Size: SH
  16. Connect the water hoses (3) to the throttle body.
  17. Connect the automatic transmission throttle cable (1) to the throttle body (automatic transmission only).
  18. Connect the accelerator cable (2) to the throttle body.

    19. Object Number: 648016 Size: SH
  19. Install the air cleaner upper case, the intake air hose, the intake air pipe (2) and the surge tank pipe (1) as one component.
  20. Install the fuel injector sight shield.
  21. Install the Front Suspension support brace. Refer to Front Suspension Support Brace Replacement in Front Suspension.
  22. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  23. Connect the negative battery cable.

    24. Tighten
    Tighten the bolt to 8 N·m (6 lb ft).

  24. Upon completion of the installation, start the engine and check for fuel and engine coolant leaks.