GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2006 🢒 HHR 🢒 Vehicle Control Systems 🢒 Vehicle DTC Information 🢒 Intake Manifold Replacement

Removal Procedure

    Object Number: 1623764 Size: SH
  1. Remove the throttle body. Refer to Throttle Body Assembly Replacement .
  2. Disconnect the fuel injector electrical connector (2).

    3. Object Number: 1627740 Size: SH
  3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
  4. Disconnect the engine harness clips (2 and 4) from the intake manifold.
  5. Lower the vehicle.
  6. Remove the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement .
  7. Disconnect the fuel injector electrical connector clip (3) from the intake manifold.

    8. Object Number: 1628035 Size: SH
  8. Reposition the vacuum brake booster hose clamp at the intake manifold.
  9. Remove the vacuum brake booster hose from the intake manifold.

    10. Object Number: 1623766 Size: SH
  10. Disconnect the evaporative emission (EVAP) canister purge tube from the intake manifold and the EVAP solenoid. Refer to Plastic Collar Quick Connect Fitting Service .
  11. Remove the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement .

    12. Object Number: 1623769 Size: SH
  12. Remove the intake manifold lower bolts.

    13. Object Number: 1571773 Size: SH
  13. Remove the intake manifold upper bolt and nuts.
  14. Remove the intake manifold.

    15. Important: The intake manifold O-ring seals are reusable, only replace the seals if damage has occurred.

  15. Inspect the intake manifold O-ring seals.

Installation Procedure

    Object Number: 1571773 Size: SH
  1. Install NEW intake manifold O-ring seals if necessary.
  2. Install the intake manifold.
  3. Install the intake manifold upper bolt and nuts.

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


    Object Number: 1623769 Size: SH
  4. Install the intake manifold lower bolts.

    5. Tighten
    Tighten the bolts/nuts to 10 N·m (89 lb in).


    Object Number: 1623766 Size: SH
  5. Install the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement .
  6. Connect the EVAP canister purge tube to the intake manifold and the EVAP solenoid. Refer to Plastic Collar Quick Connect Fitting Service .

    7. Object Number: 1628035 Size: SH
  7. Install the vacuum brake booster hose to the intake manifold.
  8. Position the vacuum brake booster hose clamp at the intake manifold.

    9. Object Number: 1627740 Size: SH
  9. Connect the fuel injector electrical connector clip (3) to the intake manifold.
  10. Install the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement .
  11. Raise and support the vehicle.
  12. Connect the engine harness clips (2 and 4) to the intake manifold.
  13. Lower the vehicle.

    14. Object Number: 1623764 Size: SH
  14. Connect the fuel injector electrical connector (2).
  15. Install the throttle body. Refer to Throttle Body Assembly Replacement .