Intake Manifold Removal

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: Never attempt to remove the intake manifold from a hot engine, allow the engine to cool to ambient temperature. The intake manifold is made of a composite plastic and can be damaged if it is removed when the engine is hot.

Remove the EVAP emission canister valve tube (1).

Fig 1: View Of EVAP Emission Canister Valve Tube
Courtesy of GENERAL MOTORS CORP.
Remove the EVAP emission canister valve (2).
Remove the throttle body and the accelerator control cable bracket.

Fig 2: Exploded View Of Throttle Body & Accelerator Control Cable Bracket
Courtesy of GENERAL MOTORS CORP.
Remove fuel pipes and clip. Remove the fuel rail assembly.

Fig 3: Exploded View Of Fuel Rail Assembly
Courtesy of GENERAL MOTORS CORP.
Remove the fuel injector tip insulators and discard.

Fig 4: View Of Fuel Injector Tip Insulators
Courtesy of GENERAL MOTORS CORP.
Remove the intake manifold retaining nuts and bolts.
Remove the intake manifold.

Fig 5: Removing & Installing Intake Manifold
Courtesy of GENERAL MOTORS CORP.
Remove the intake manifold gasket, if necessary. The gasket can be used again if it is not damaged.
If the intake manifold needs to be replaced, transfer the throttle body to the new intake manifold.