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Intake Manifold Installation

WARNING: This page is about a different car, the 2008 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Intake Manifold
    GM1769718Courtesy of GENERAL MOTORS CORP.
  1. Install a NEW intake manifold gasket.
  2. Install the intake manifold.
    3. NOTE: Refer to Fastener Notice .
  3. Install the intake manifold bolts and nuts.

    Tighten: 

    1. Tighten the intake manifold bolts to 22 N.m (16 lb ft).
    2. Tighten the intake manifold nuts to 22 N.m (16 lb ft).

    4. Fig 2: Identifying Intake Manifold Brace
    GM1769715Courtesy of GENERAL MOTORS CORP.
  4. Install the intake manifold brace.
  5. Install the intake manifold brace bolt.

    Tighten:  Tighten the intake manifold brace bolt to 22 N.m (16 lb ft).

  6. Connect the rear knock sensor to the intake manifold brace.
    7. Fig 3: View Of Throttle Body & Bolts
    GM1769706Courtesy of GENERAL MOTORS CORP.
  7. Install the throttle body.
  8. Install the throttle body bolts.

    Tighten:  Tighten the throttle body bolts to 10 N.m (89 lb in).

    9. Fig 4: View Of High Pressure Fuel Pump Cover
    GM1769666Courtesy of GENERAL MOTORS CORP.
  9. Install the high pressure fuel pump noise insulator.
  10. Install the high pressure fuel pump cover.
  11. Install the high pressure fuel pump cover bolts.

    Tighten:  Tighten the fuel pump cover bolts to 10 N.m (89 lb in).

    12. Fig 5: Identifying Fuel Feed Line
    GM1769663Courtesy of GENERAL MOTORS CORP.
  12. Lubricate the high pressure fuel pump fuel feed line connection threads with clean 5W30 engine oil.
  13. Install the fuel feed line.
  14. Install the fuel feed line bolts.
  15. Connect the low pressure fuel line nut.

    Tighten: 

    1. Tighten the low pressure fuel line nut to 30 N.m (22 lb ft).
    2. Tighten the fuel feed line bolts to 10 N.m (89 lb in).

    16. Fig 6: Identifying AIR Bypass Valve Tank Assembly
    GM2045492Courtesy of GENERAL MOTORS CORP.
  16. If the engine is equipped with a charger AIR bypass tank assembly, complete the following procedure:
    1. Install the charger AIR bypass valve tank assembly.
    2. Tighten the charger AIR bypass valve tank assembly bolt.

      Tighten:  Tighten the charger AIR bypass valve tank assembly bolt to 25 N.m (18 lb ft).

    3. Install the charger AIR bypass valve tank assembly nut.

      Tighten:  Tighten the charger AIR bypass valve tank assembly nut to 25 N.m (18 lb ft).

      4. IMPORTANT: Ensure proper connection of the charger AIR bypass tube assemblies and retaining clips to maintain proper pressure. Connect each tube to the appropriate location. The tube with retaining clamp located on the charger AIR bypass valve tank assembly left side connects to the charger AIR bypass valve solenoid. The right side permanently attached tube connects to the intake manifold.
    4. Connect the appropriate charger AIR bypass tube assembly to the intake manifold.
    17. Fig 7: View Of AIR Bypass Tube Assembly
    GM2048166Courtesy of GENERAL MOTORS CORP.
  17. If the engine is equipped with a charger AIR bypass tank assembly, complete the following procedure:
    1. Install the charger AIR bypass valve solenoid with charger AIR bypass tube assemblies.
    2. Install the charger AIR bypass valve solenoid bolts.

      Tighten:  Tighten the charger AIR bypass valve solenoid bolts to 10 N.m (89 lb in).

      3. IMPORTANT: Ensure proper connection of the charger AIR bypass tube assemblies and retaining clips to maintain proper pressure. Connect each tube to the appropriate location.
    3. Connect the charger AIR bypass tube assemblies and clamps from the charger AIR bypass valve solenoid to the turbocharger and vehicle.
    4. Connect the final charger AIR bypass tube assembly from the charger AIR bypass valve tank assembly to the charger AIR bypass valve solenoid.
    18. Fig 8: Bypass Valve Solenoid Hoses
    GM1769657Courtesy of GENERAL MOTORS CORP.
  18. If the engine is not equipped with a charger AIR bypass tank assembly, complete the following procedure:
    1. Install the charger AIR bypass valve solenoid with charger AIR bypass tube assemblies.
    2. Install the charger AIR bypass valve solenoid bolts.

      Tighten:  Tighten the charger AIR bypass valve solenoid bolts to 10 N.m (89 lb in).

      3. IMPORTANT: Ensure proper connection of the charger AIR bypass tube assemblies and retaining clips to maintain proper pressure. Connect each tube to the appropriate location.
    3. Connect the charger AIR bypass tube assemblies and clamps.
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