GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Classic 🢒 Engine 🢒 Engine Electrical 🢒 Intake Manifold Replacement

Removal Procedure
  1. Remove the air inlet duct and resonator.
  2. Disconnect the IAC electrical connector.
  3. Disconnect the TPS electrical connector.
  4. Disconnect the MAP sensor electrical connector.
  5. Disconnect the EVAP hose.
  6. Disconnect the PCV hose.
  7. Disconnect the purge solenoid tube.
  8. Disconnect the brake booster hose.
  9. Remove the oil level indicator tube bolt.
  10. Disconnect the accelerator and cruise control cables.

    11. Object Number: 782280 Size: SH
  11. Remove the throttle body.

    12. Object Number: 870613 Size: SH
  12. Remove the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls-2.2 (L61).

    13. Object Number: 630348 Size: SH
  13. Remove the knock sensor connector from the intake manifold.

    14. Object Number: 412135 Size: SH
  14. Remove the intake manifold nuts and bolts.
  15. Remove the intake manifold.
  16. Remove the intake manifold gasket, if necessary. The gasket is reusable if the gasket is not damaged.

Installation Procedure
  1. If removed, install the intake manifold gasket.
  2. Install the intake manifold.

    3. 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.


    Object Number: 412135 Size: SH
  3. Install the intake manifold nuts and bolts.

    4. Tighten
    Tighten the intake manifold nuts and bolts to 10 N·m (89 lb in).


    Object Number: 630348 Size: SH
  4. Install the knock sensor connector to the intake manifold.

    5. Object Number: 870613 Size: SH
  5. Install the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls-2.2L (L61).

    6. Object Number: 782280 Size: SH
  6. Install the throttle body. Refer to Throttle Body Assembly Replacement in Engine Controls 2.2L.
  7. Connect the IAC electrical connector.
  8. Connect the TPS electrical connector.
  9. Connect the MAP sensor electrical connector.
  10. Connect the EVAP hose.
  11. Connect the PCV hose.
  12. Connect the purge solenoid tube.
  13. Connect the brake booster hose.
  14. Install the oil level indicator tube bolt.
  15. Connect the accelerator and the cruise control cables.
  16. Install the air inlet duct and resonator.