Removal Procedure

WARNING: This page is about a different car, the 2002 Pontiac Sunfire and 2002 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.

Relieve the fuel system pressure. Refer to FUEL SYSTEM PRESSURE RELEASE (GASOLINE) .
Remove the air cleaner inlet duct (1).

Fig 1: Air Cleaner Inlet Duct
Courtesy of GENERAL MOTORS CORP.
Remove the resonator.

Fig 2: Resonator
Courtesy of GENERAL MOTORS CORP.
Remove the resonator bracket/fuel rail cover.

Fig 3: Resonator Bracket/Fuel Rail Cover
Courtesy of GENERAL MOTORS CORP.
Disconnect the vacuum hoses at the throttle body.
Remove the throttle body. Refer to THROTTLE BODY .

Fig 4: Throttle Body
Courtesy of GENERAL MOTORS CORP.
Disconnect the MAP sensor.

Fig 5: MAP Sensor
Courtesy of GENERAL MOTORS CORP.
Remove fuel rail. Refer to FUEL RAIL & INJECTORS .
Raise vehicle.
Disconnect the following components:
- EVAP purge solenoid
- Camshaft sensor
- Crankshaft sensor
- VSS
- Knock sensor
- Back-up lamp switch
- Oxygen sensor
- Oil pressure switch
Lower vehicle.
Unroute wiring harness.
Remove the intake manifold attaching nuts and the bolts.

Fig 6: Intake Manifold Nuts

Courtesy of GENERAL MOTORS CORP.

Remove the intake manifold from the engine.
Clean the mating surfaces on the intake manifold and the cylinder head.
Inspect the manifold for cracks, broken flanges, and gasket surface damage.

Fig 7: Intake Manifold Assembly
Courtesy of GENERAL MOTORS CORP.