GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Vivant 🢒 Engine 🢒 Engine Mechanical - 2.0L (L34 GMDAT) 🢒 Intake Manifold Replacement

Removal Procedure

    Object Number: 1263236 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. Caution: Refer to Battery Disconnect Caution in the Preface section.

  3. Disconnect the negative battery cable.
  4. Remove the air filter housing bolts.
  5. Remove the air filter housing assembly.

    6. Object Number: 1263802 Size: SH
  6. Disconnect the manifold air temperature (MAT) sensor connector.
  7. Disconnect the breather hose from the valve cover.
  8. Remove the air intake tube from the throttle body.

    9. Object Number: 1263822 Size: SH
  9. Disconnect the throttle cable from the throttle body and the intake manifold.
  10. Disconnect the vacuum hose at the fuel pressure regulator.

    11. Object Number: 1263823 Size: SH
  11. Remove the fuel injector rail and fuel injectors as an assembly. refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls - 2.0L.
  12. Remove the engine harness wire bracket bolts from the rear of the intake manifold.
  13. Remove the evaporative emission (EVAP) canister purge solenoid bracket bolt and reposition the canister purge solenoid clear of the repair area.

    14. Object Number: 1263805 Size: SH
  14. Remove the alternator upper bracket colts.
  15. Remove the alternator upper bracket.

    16. Object Number: 1263827 Size: SH
  16. Disconnect the brake vacuum hose from the intake manifold.
  17. Remove the engine control module (ECM) ground terminal bolt from the intake manifold.
  18. Remove the intake manifold support bracket upper bolt to the intake manifold.

    19. Object Number: 1263746 Size: SH
  19. Remove the throttle body assembly. Refer to Throttle Body Assembly Replacement in Engine Controls - 2.0L.
  20. Remove the valve cover. Refer to Valve Rocker Arm Cover Replacement .
  21. Remove the intake manifold retaining bolt/nuts in the sequence shown.

    22. Caution: Refer to Safety Glasses Caution in the Preface section.

  22. Remove the intake manifold gasket.
  23. Clean the sealing surfaces of the intake manifold and the cylinder head.

Installation Procedure

    Object Number: 1263746 Size: SH
  1. Install the intake manifold gasket.

    2. Notice: Refer to Fastener Notice in the Preface section.

  2. Install the intake manifold retaining bolt/nuts in the sequence shown.

    3. Tighten
    Tighten the manifold bolt/nuts to 18 N·m (13 lb ft).

  3. Install the valve cover. Refer to Valve Rocker Arm Cover Replacement .
  4. Install the throttle body assembly. Refer to Throttle Body Assembly Replacement .

    5. Object Number: 1263827 Size: SH
  5. Install the intake manifold support bracket upper bolt to the intake manifold.

    6. Tighten
    Tighten the support bracket upper bolt to 20 N·m (15 lb ft).

  6. Install the ECM ground terminal bolt from the intake manifold.
  7. Connect the brake vacuum hose from the intake manifold.

    8. Object Number: 1263805 Size: SH
  8. Install the alternator upper bracket.
  9. Install the alternator upper bracket bolts.

    10. Tighten
    Tighten the upper bracket bolt to 35 N·m (26 lb ft).


    Object Number: 1263823 Size: SH
  10. Install the EVAP canister purge solenoid bracket bolt and reposition the canister purge solenoid clear of the repair area.
  11. Install the engine harness wire bracket bolts from the rear of the intake manifold.
  12. Install the fuel injector rail and fuel injectors as an assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement .

    13. Object Number: 1263822 Size: SH
  13. Connect the vacuum hose at the fuel pressure regulator.
  14. Connect the throttle cable from the throttle body and the intake manifold.

    15. Object Number: 1263802 Size: SH
  15. Install the air intake tube from the throttle body.
  16. Connect the breather hose from the valve cover.
  17. Install the MAT sensor connector.

    18. Object Number: 1263236 Size: SH
  18. Install the air filter housing assembly.
  19. Install the air filter housing bolts.
  20. Install the fuel pump fuse.
  21. Connect the negative battery cable.