Intake Manifold Installation

WARNING: This page is about a different car, the 2004 Pontiac Sunfire and 2004 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Refer to FASTENER NOTICE in Cautions and Notices.

Install the intake manifold studs in the manifold face.
Tighten: Tighten the intake manifold studs to 5 N.m (44 lb in).

Fig 1: View Of Intake Manifold Studs
Courtesy of GENERAL MOTORS CORP.
Install a new intake manifold gasket on the intake manifold.
Install the intake manifold.

Fig 2: Removing & Installing Intake Manifold
Courtesy of GENERAL MOTORS CORP.
Install the intake manifold bolts and nuts. Follow the tightening sequence.
Tighten: Tighten the bolts and nuts to 10 N.m (89 lb in).
Lubricate the fuel injector tip insulators with engine oil.
Install new fuel injector tip insulators.

Fig 3: View Of Fuel Injector Tip Insulators
Courtesy of GENERAL MOTORS CORP.
Lubricate the fuel injector oil rings with engine oil.
Install the fuel rail assembly.

Fig 4: Exploded View Of Fuel Rail Assembly
Courtesy of GENERAL MOTORS CORP.
Install the fuel rail stud.
Tighten: Tighten the stud to 10 N.m (89 lb in).
Install a new throttle body gasket.
Install the throttle body and the accelerator control cable bracket.
Tighten: Tighten the bolts and nuts to 10 N.m (89 lb in).

Fig 5: Exploded View Of Throttle Body & Accelerator Control Cable Bracket
Courtesy of GENERAL MOTORS CORP.

IMPORTANT: Ensure that the rear metal tab of the EVAP emission canister valve is resting on the power steering pump metal body.
Install the EVAP emission canister valve (2).
Tighten: Tighten the EVAP canister valve to 22 N.m (16 lb ft).
Install the EVAP emission canister valve tube (1).

Fig 6: View Of EVAP Emission Canister Valve Tube
Courtesy of GENERAL MOTORS CORP.