GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2004 🢒 Malibu 🢒 Engine 🢒 Engine Mechanical - 2.2L (L61) 🢒 Intake Manifold Replacement

Removal Procedure
  1. Remove the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator Replacement in Engine Controls - 2.2L (L61).
  2. Remove the throttle body. Refer to Throttle Body Assembly Replacement in Engine Controls - 2.2L (L61).
  3. Disconnect the PCV hose.
  4. Disconnect the purge solenoid tube.
  5. Disconnect the brake booster hose.
  6. Remove the oil level indicator tube bolt.
  7. Remove the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls - 2.2L (L61).
  8. Disconnect the knock sensor electrical connector.

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

    10. Object Number: 412135 Size: SH
  10. Remove the intake manifold nuts and bolts.
  11. Remove the intake manifold.

    12. Important: The intake manifold gasket is reusable, only replace the gasket if damage has occurred.

  12. If applicable, remove the intake manifold gasket.

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

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


    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 harness connector to the intake manifold.
  5. Connect the knock sensor electrical connector.
  6. Install the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls -2.2L (L61).
  7. Install the throttle body.
  8. Install the oil level indicator tube bolt.

    9. Tighten
    Tighten the oil level indicator tube bolt to 10 N·m (89 lb in).

  9. Connect the brake booster hose.
  10. Connect the purge solenoid tube.
  11. Connect the PCV hose.
  12. Install the throttle body. Refer to Throttle Body Assembly Replacement in Engine Controls - 2.2L (L61).
  13. Install the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator Replacement in Engine Controls - 2.2L (L61).