GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2002 🢒 Malibu 🢒 Engine 🢒 Engine Controls - 3.1L 🢒 Upper Intake Manifold Replacement

Removal Procedure

    Object Number: 258777 Size: SH
  1. Remove the top half of the air cleaner assembly. Refer to Air Cleaner Element Replacement in Engine Controls - 3.1L.
  2. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  3. Remove the brake vacuum pipe at the plenum.
  4. Disconnect the fuel pressure regulator vacuum hose (1) from the fuel pressure regulator (3) and the PCV valve (2).
  5. Remove the electronic ignition coil and module assembly. Refer to Ignition Control Module Replacement in Engine Controls.
  6. Remove throttle cable bracket with cables.

    7. Object Number: 73898 Size: SH
  7. Remove the EVAP canister purge solenoid.

    8. Object Number: 69065 Size: SH
  8. Disconnect the throttle position (TP) sensor.

    9. Object Number: 69056 Size: SH
  9. Disconnect the idle air control (IAC) sensor.
  10. Disconnect the fuel injector harness.

    11. Object Number: 12615 Size: SH
  11. Remove the manifold absolute pressure (MAP) sensor (1). Refer to Manifold Absolute Pressure Sensor Replacement in Engine Controls.
  12. Remove EGR pipe. Refer to Exhaust Gas Recirculation Pipe Replacement in Engine Controls.

    13. Object Number: 466875 Size: SH
  13. Remove inlet and outlet hoses from throttle body (1).

    14. Object Number: 325936 Size: SH
  14. Remove the upper intake manifold bolts.

    15. Object Number: 96379 Size: SH
  15. Remove the upper intake manifold and gaskets.
  16. Clean the gasket surfaces.

Installation Procedure

    Object Number: 325936 Size: SH
  1. Install the upper intake manifold gaskets on the manifold.

    2. 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.

  2. Apply thread lock GM P/N 12345382 to the threads of the bolts.

    3. Install the upper intake manifold bolts.

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


    Object Number: 12615 Size: SH
  3. Install the MAP sensor (1). Refer to Manifold Absolute Pressure Sensor Replacement in Engine Controls.
  4. Install EGR pipe. Refer to Exhaust Gas Recirculation Pipe Replacement in Engine Controls.

    5. Object Number: 466875 Size: SH
  5. Install inlet and outlet hoses from throttle body (1).

    6. Object Number: 16290 Size: SH
  6. Install the vacuum hose (1) to the fuel pressure regulator (3) and the crankcase ventilation valve (2).

    7. Object Number: 69065 Size: SH
  7. Connect the TP sensor.

    8. Object Number: 69056 Size: SH
  8. Connect the IAC.
  9. Connect the fuel injector harness.

    10. Object Number: 73898 Size: SH
  10. Install the EVAP canister purge solenoid.

    11. Object Number: 258777 Size: SH
  11. Install the electronic ignition coil and module assembly. Refer to Ignition Control Module Replacement in Engine Controls.

    12. Object Number: 12735 Size: SH
  12. Install throttle cable bracket and cables to throttle body.
  13. Install the top half of the air cleaner assembly.
  14. Install the brake vacuum pipe.
  15. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  16. Inspect for proper fluid levels.
  17. Inspect for leaks.