LEMON Manuals: Even more car manuals for everyone
Home >> Chevrolet >> 2001 >> Cavalier LS, 2.2 4 >> Repair and Diagnosis >> External Pages >> Different car >> Section 149 (Engine Mechanical - 2.4L (On-Vehicle)) >> Repair Instructions >> Intake Manifold Replacement >> Installation Procedure

Installation 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.

Important:  The engine and the manifold should be at ambient temperature when assembled. Do not attempt to install a cold manifold on a hot engine.

  1. Install the intake manifold and the gasket. If the gasket is damaged, install a new one with the stamped numbers facing towards the manifold surface.
  2. Install the intake manifold nut and bolts. Tighten the nuts and bolts in sequence (1,2,3,4,5,6 and 7) to 24 N.m (18 ft lbs).
    3. Fig 1: Intake Manifold Tightening Sequence
    G01777571Courtesy of GENERAL MOTORS CORP.
  3. Install wiring harness to retainer on bottom of intake.
  4. Install brake booster vacuum line to throttle body.
  5. Install the stud ended generator mount bolt.
  6. Install the accelerator control cable bracket.
  7. Connect the vacuum hoses to the fuel regulator and to the EVAP canister purge solenoid.

    Important:  If the IAT sensor is removed, apply sealant GM P/N 1052080 (Canadian P/N 10953480) or equivalent to its threads before installation.

  8. Connect the following electrical connections:
    • MAP sensor
    • IAT sensor
    • EVAP canister purge solenoid
    • Fuel injector harness
  9. Install the air cleaner resonator and duct.
scientia non olet · About LEMON Manuals