GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Holden 🢒 2009 🢒 Sportwagon 🢒 Preface 🢒 Cautions and Notices 🢒 Intake Manifold Cleaning and Inspection

Upper Intake Manifold Cleaning Procedure
  1. Remove any remaining gasket and/or gasket material from the following:
    2. • Throttle body.
    • Intake manifold.
  2. Clean the following intake manifold areas in solvent.
    3. • Intake manifold gasket sealing areas.
    • Intake manifold passages.
    • Brake booster hose passage.
    • Evaporative emission (EVAP) solenoid passage.
    • Positive Crankcase Ventilation (PCV) vacuum hose passages.

    Caution: Refer to Safety Glasses Caution in the Preface section.

  3. Dry the upper intake manifold and throttle body with compressed air.

Inspection Procedure
  1. Inspect the upper intake manifold for the following conditions:
    2. • Damage, debris or restrictions to the brake vacuum booster hose port.
    • Damage to the throttle body bolt holes.
    • Damage, debris or restrictions to the PCV system hose ports.
    • Damage to the intake manifold bolt bosses.
    • Damage to the EVAP purge solenoid mounting boss.
    • Damage, debris or restrictions to the EVAP purge solenoid port.
    • Damage, debris or restrictions in the vacuum passage.
    • Damage to the intake manifold runner control flap mounting bosses.
    • Damage, debris or restrictions to the intake manifold runner control flap port.
    • Damage to the intake manifold runner control flap components.
    • Gouges or damage to the upper intake manifold sealing surfaces.
    • Damage to the gasket sealing surface for the throttle body.

    Object Number: 1961586 Size: SH
  2. Inspect the upper intake manifold sealing surface for warpage.
    3. 2.1. Locate a straight edge (1) across the upper-to-lower intake manifold sealing surface (3).
    2.2. Insert a feeler gauge (2) between the upper-to-lower intake manifold sealing surface (3) and the straight edge (1). An upper intake manifold with warpage in excess of 0.05 mm (0.020 in) must be replaced.
  3. Repair or replace the upper intake manifold as necessary.

Lower Intake Manifold Cleaning Procedure
  1. Remove any remaining gasket and/or gasket material from the following:
    2. • Upper-to-lower intake manifold sealing surface.
    • Cylinder head-to-lower intake manifold sealing surface.
  2. Clean the following intake manifold areas in solvent.
    3. • Intake manifold gasket sealing surfaces.
    • Intake manifold passages.

    Caution: Refer to Safety Glasses Caution in the Preface section.

  3. Dry the intake manifold with compressed air.

Inspection Procedure
  1. Inspect the lower intake manifold for the following conditions:
    2. • Damage, debris or restrictions to the lower intake manifold ports
    • Damage to the fuel rail mounting bolt holes
    • Damage to the fuel rail
    • Gouges or damage to the intake manifold sealing surfaces
    • Damage to the lower intake manifold bolt bosses
    • Damage to the fuel injector ports

    Object Number: 1961756 Size: SH
  2. Inspect the lower intake manifold sealing surfaces for warpage.
    3. 2.1. Locate a straight edge (1) across the lower intake manifold sealing surfaces (2).
    2.2. Insert a feeler gauge (3) between the lower intake manifold sealing surfaces (2) and the straight edge (1). A lower intake manifold with warpage in excess of 0.5 mm (0.020 in) must be replaced.
  3. Repair or replace the lower intake manifold as necessary.