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Intake Manifold Installation

WARNING: This page is about a different car, the 2010 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Intake Manifold
    GM1769718Courtesy of GENERAL MOTORS CORP.
  1. Install a NEW intake manifold gasket.
  2. Install the intake manifold.
    3. CAUTION: Refer to Fastener Caution .
  3. Install the intake manifold bolts and nuts finger tight.
    4. Fig 2: Identifying Intake Manifold Bolt & Nut Tightening Sequence
    GM2215893Courtesy of GENERAL MOTORS CORP.
  4. Tighten the intake manifold bolts and nuts in sequence a first pass to 5 N.m (44 lb in).
  5. Tighten the intake manifold bolts and nuts in sequence a final pass to 25 N.m (18 lb ft).
    6. Fig 3: Intake Manifold Brace
    GM1769715Courtesy of GENERAL MOTORS CORP.
  6. Install the intake manifold brace.
  7. Install the intake manifold brace bolt and nut and tighten to 25 N.m (18 lb ft).
  8. Connect the rear knock sensor to the intake manifold brace.
    9. Fig 4: Throttle Body & Bolts
    GM1769706Courtesy of GENERAL MOTORS CORP.
  9. Install the throttle body.
  10. Install the throttle body bolts and tighten to 10 N.m (89 lb in).
    11. Fig 5: Fuel Feed Line
    GM1769663Courtesy of GENERAL MOTORS CORP.
  11. Lubricate the high pressure fuel pump fuel feed line connection threads with clean 5W30 engine oil.
  12. Install the fuel feed line.
  13. Install the fuel feed line bolts.
  14. Connect the low pressure fuel line nut.
    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) .
    15. Fig 6: High Pressure Fuel Pump Cover
    GM1769666Courtesy of GENERAL MOTORS CORP.
  15. Install the high pressure fuel pump noise insulator.
  16. Install the high pressure fuel pump cover.
  17. Install the high pressure fuel pump cover bolts and tighten to 10 N.m (89 lb in).
    18. Fig 7: View Of AIR Bypass Tube Assembly
    GM2048166Courtesy of GENERAL MOTORS CORP.
  18. Install the charger AIR bypass valve solenoid with charger AIR bypass tube assemblies.
  19. Install the charger AIR bypass valve solenoid bolts and tighten to 10 N.m (89 lb in).
    20. NOTE: Ensure proper connection of the charger AIR bypass tube assemblies and retaining clips to maintain proper pressure. Connect each tube to the appropriate location.
  20. Connect the charger AIR bypass tube assemblies and clamps from the charger AIR bypass valve solenoid to the turbocharger and vehicle.
    21. Fig 8: Identifying AIR Bypass Valve Tank Assembly
    GM2045492Courtesy of GENERAL MOTORS CORP.
  21. Install the charger AIR bypass valve tank assembly (1).
  22. Tighten the charger AIR bypass valve tank assembly bolt to 25 N.m (18 lb ft).
  23. Install the charger AIR bypass valve tank assembly nut (2) and tighten to 25 N.m (18 lb ft).
    24. NOTE: 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.
  24. Connect the appropriate charger AIR bypass tube assembly to the intake manifold.
  25. Connect the final charger AIR bypass tube assembly from the charger AIR bypass valve tank assembly to the charger AIR bypass valve solenoid.
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