GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2007 🢒 Vivant 🢒 Engine 🢒 Engine Mechanical - 1.6L (L91) 🢒 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: 1263231 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. Disconnect the idle air control (IAC) valve connector.
  10. Disconnect the throttle position (TP) sensor connector.
  11. Disconnect the coolant temperature (CTS) sensor connector.
  12. Disconnect the ECT connector.
  13. Disconnect the heater inlet hose from the cylinder head.
  14. Disconnect the surge tank coolant hose at the throttle body.

    15. Object Number: 1263606 Size: SH
  15. Disconnect the throttle cable from the throttle body and the intake manifold.
  16. Disconnect the vacuum hose at the fuel pressure regulator.

    17. Object Number: 1263566 Size: SH
  17. Remove the fuel injector rail and fuel injectors as an assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement .
  18. Remove the intake manifold support bracket upper bolt.
  19. Remove the intake manifold support bracket lower bolt.
  20. Remove the evaporative emission (EVAP) canister purge solenoid bracket bolt and reposition the canister purge solenoid clear of the repair area.

    21. Object Number: 1263620 Size: SH
  21. Remove the intake manifold retaining bolts/nuts in the sequence shown.
  22. Remove the intake manifold.
  23. Remove the intake manifold gasket.
  24. Clean the sealing surfaces of the intake manifold and the cylinder head.

Installation Procedure

    Object Number: 1263620 Size: SH
  1. Install the intake manifold gasket.
  2. Install the intake manifold.

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

  3. Install the intake manifold retaining bolts/nuts in the sequence shown.

    4. Tighten
    Tighten the manifold bolts/nuts to 25 N·m (18 lb ft).


    Object Number: 1263566 Size: SH
  4. Install the EVAP canister purge solenoid bracket bolt and reposition the canister purge solenoid.
  5. Install the intake manifold support bracket lower bolt.

    6. Tighten
    Tighten the lower bolts to 40 N·m (30 lb ft).

  6. Install the intake manifold support bracket upper bolt.

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

  7. Install the fuel injector rail and fuel injectors as an assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement .

    8. Object Number: 1263606 Size: SH
  8. Connect the vacuum hose at the fuel pressure regulator.
  9. Connect the throttle cable from the throttle body and the intake manifold.

    10. Object Number: 1263231 Size: SH
  10. Connect the surge tank coolant hose at the throttle body.
  11. Connect the heater inlet hose to the cylinder head.
  12. Connect the ECT sensor connector.
  13. Connect the coolant temperature sensor connector.
  14. Connect the TP sensor connector.
  15. Connect the IAC valve connector.
  16. Install the air intake tube to the throttle body.
  17. Connect the breather hose from the valve cover.
  18. Connect the MAT sensor connector.

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