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Home >> Chevrolet >> 2005 >> Malibu LS >> Repair and Diagnosis >> External Pages >> Different car >> Section 958 (Engine Mechanical - 3.6L - Repair Instructions - Off Vehicle (2 Of 3)) >> Repair Instructions - Off Vehicle (2 Of 3) >> Intake Manifold Cleaning and Inspection >> Inspection Procedure

Inspection Procedure

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    Fig 1: Identifying Upper Intake Manifold Components
    GM1849054Courtesy of GENERAL MOTORS CORP.
  1. Inspect the upper intake manifold for the following conditions:
    • Damage, debris or restrictions to the MAP sensor port (1)
    • Damage to the intake manifold bolt bosses (2)
    • Damage to the component bolt bosses and threads (3)
    • Damage, debris or restrictions to the brake vacuum booster hose port (4)
    • Damage, debris or restrictions to the PCV system hose ports (5)
    • Damage, debris or restrictions to the EVAP system hose ports (6)
    • Damage to the throttle body bolt holes (7)
    2. Fig 2: View Of Intake Manifold
    GM1849057Courtesy of GENERAL MOTORS CORP.
  2. Inspect the upper intake manifold for the following conditions:
    • Damage to the component bolt bosses and threads (1)
    • Damage to the intake manifold bolt bosses (2)
    • Damage to the intake manifold tuning valve mounting threads (3)
    3. Fig 3: Identifying Upper Intake Manifold Components
    GM1849061Courtesy of GENERAL MOTORS CORP.
  3. Inspect the upper intake manifold for the following conditions:
    • Damage to the intake manifold tuning valve mounting bosses (1)
    • Damage, debris or restrictions to the intake manifold tuning valve port (2)
    • Damage to the intake manifold tuning valve bushing (3)
    4. Fig 4: Inspecting Upper Intake Manifold For Gouges
    GM1408571Courtesy of GENERAL MOTORS CORP.
  4. Inspect the upper intake manifold for the following conditions:
    • Gouges or damage to the upper intake manifold sealing surfaces (1)
    • Damage to the gasket sealing surface (2) for the throttle body
    5. Fig 5: View Of Upper Intake Manifold Sealing Surface For Warpage
    GM1849064Courtesy of GENERAL MOTORS CORP.
  5. Inspect the upper intake manifold sealing surface for warpage.
    1. Locate a straight edge across the upper-to-lower intake manifold sealing surface.
    2. Insert a feeler gauge between the upper intake manifold and the straight edge. An upper intake manifold with warpage in excess of 0.50 mm (0.020 in) must be replaced.
  6. Repair or replace the upper intake manifold as necessary.


    Fig 1: Inspecting Lower Intake Manifold For Damage
    GM1211107Courtesy of GENERAL MOTORS CORP.
  1. Inspect the lower intake manifold for the following conditions:
    • Damage, debris or restrictions to the lower intake manifold ports
    • Damage to the fuel rail mounting bolt holes
    • Damage to the fuel rail
    2. Fig 2: Checking Lower Intake Manifold For Damage
    GM1211110Courtesy of GENERAL MOTORS CORP.
  2. Inspect the lower intake manifold for the following conditions:
    • Gouges or damage to the intake manifold sealing surfaces
    • Damage to the lower intake manifold bolt bosses
    • Damage to the fuel injector ports
    3. Fig 3: Measuring Lower Intake Manifold For Warpage
    GM1211113Courtesy of GENERAL MOTORS CORP.
  3. Inspect the lower intake manifold sealing surfaces for warpage.
    1. Locate a straight edge across the lower intake manifold sealing surfaces.
    2. Insert a feeler gauge between the lower intake manifold and the straight edge. A lower intake manifold with warpage in excess of 0.5 mm (0.020 in) must be replaced.
  4. Repair or replace the lower intake manifold as necessary.
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