GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Holden 🢒 2009 🢒 Barina 🢒 Preface 🢒 Dangers, Warnings, and Cautions 🢒 Intake Manifold Replacement

Removal Procedure

    Object Number: 1241528 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. Warning: Refer to Battery Disconnect Warning in the Preface section.

  3. Disconnect the negative battery cable.
  4. Disconnect the engine control module (ECM) ground terminal from the intake manifold.

    5. Object Number: 1241530 Size: SH
  5. Drain the engine coolant. Refer to Cooling System Draining and Filling.
  6. Disconnect the intake air temperature (IAT) sensor connector.
  7. Disconnect the air intake tube from the throttle body.

    8. Object Number: 1241532 Size: SH
  8. Disconnect the idle air control valve (IAC) connector.
  9. Disconnect the throttle position (TP) sensor connector.

    10. Object Number: 1241555 Size: SH
  10. Disconnect the heater inlet hose from the coolant distributor beneath the intake manifold.
  11. Disconnect the surge tank coolant hose at the throttle body.
  12. Disconnect all of the necessary vacuum hoses, including the vacuum hose at the fuel pressure regulator and the brake booster vacuum hose at the intake manifold.

    13. Object Number: 1241550 Size: SH
  13. Disconnect the throttle cable from the throttle body and the intake manifold.
  14. Remove the 2 throttle cable bracket bolts and the throttle cable bracket.
  15. Disconnect the fuel feed line from the fuel rail.

    16. Object Number: 1241669 Size: SH
  16. Disconnect the fuel injector connectors from the fuel injectors.
  17. Remove the 2 retaining bolts from the fuel injector rail.
  18. Remove the fuel injector rail and fuel injectors as an assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement.

    19. Object Number: 1241549 Size: SH
  19. Remove the serpentine accessory drive belt.
  20. Remove the alternator bracket and the bolt.
  21. Remove the 3 intake manifold support bracket retaining bolts from the coolant distributor and the engine block.
  22. Remove the intake manifold support bracket.

    23. Object Number: 1241681 Size: SH
  23. Remove the intake manifold retaining nuts and the engine lift bracket bolt in the sequence shown.

    24. Object Number: 1241672 Size: SH
  24. Remove the intake manifold.
  25. Remove the intake manifold gasket.

    26. Warning: Refer to Safety Glasses Warning in the Preface section.

  26. Clean the sealing surfaces of the intake manifold and the cylinder head.

Installation Procedure

    Object Number: 1241675 Size: SH
  1. Install the intake manifold gasket.
  2. Install the intake manifold.

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

  3. Install the intake manifold retaining nuts and the engine lift bracket bolt in the sequence shown.

    4. Tighten

        • Tighten the intake manifold retaining nuts in the sequence shown to 22 N·m (16 lb ft).
        • Tighten the engine lift bracket bolt to 25 N·m (18 lb ft).

    Object Number: 1241549 Size: SH
  4. Install the intake manifold support bracket.
  5. Install the intake manifold support bracket retaining bolts.

    6. Tighten
    Tighten the intake manifold support bracket retaining bolts to 25 N·m (18 lb ft).

  6. Install the alternator bracket and the bolts.

    7. Tighten
    Tighten the alternator bracket retaining bolts to 25 N·m (18 lb ft).

    Caution: Refer to Belt Dressing Caution in the Preface section.

  7. Install the serpentine accessory drive belt.

    8. Object Number: 1241669 Size: SH
  8. Install the fuel rail and the fuel injectors as an assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement.
  9. Install the fuel rail retaining bolts.

    10. Tighten
    Tighten the fuel rail retaining bolts to 25 N·m (18 lb ft).

  10. Connect the fuel feed line to the fuel rail.

    11. Object Number: 1241555 Size: SH
  11. Connect the throttle cable to the intake manifold and the throttle body.
  12. Connect the fuel injector connectors to the fuel injectors.
  13. Connect all of the vacuum lines that were previously disconnected.
  14. Connect the heater inlet hose to the coolant distributor beneath the intake manifold.
  15. Connect the surge tank coolant hose to the throttle body.
  16. Connect the IAC valve connector.
  17. Connect the throttle position sensor connector.

    18. Object Number: 1241530 Size: SH
  18. Connect the air intake tube to the throttle body.
  19. Connect the IAT sensor connector.
  20. Connect the ECM ground terminal to the intake manifold.
  21. Connect the negative battery cable.
  22. Install the fuel pump fuse.
  23. Refill the engine cooling system. Refer to Cooling System Draining and Filling.