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Home >> Chevrolet >> 2012 >> Cruze Eco, Automatic Trans >> Repair and Diagnosis >> External Pages >> Different car >> Section 89 (Engine Mechanical - 2.0L) >> Repair Instructions - On Vehicle >> Intake Manifold Replacement >> Installation Procedure

Installation Procedure

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: Throttle Body
    GM1825561Courtesy of GENERAL MOTORS CORP.
  1. If replacing the intake manifold perform the following steps, otherwise proceed to step 11.
  2. Inspect the throttle body seal and replace if necessary.
  3. Install the throttle body seal and position the throttle body.
    4. CAUTION: Refer to Fastener Caution .
  4. Install the throttle body bolts and tighten to 10 N.m (89 lb in).
  5. Turn the intake manifold right side up.
    6. Fig 2: EVAP Canister Purge Solenoid
    GM1825560Courtesy of GENERAL MOTORS CORP.
  6. Inspect the EVAP purge solenoid and MAP sensor O-ring seals, replace if necessary.
  7. Ensure that the EVAP purge solenoid O-ring seal (4) is installed on the EVAP purge solenoid (5).
  8. Install the EVAP purge solenoid (5) and bolt (6) and tighten the bolt to 10 N.m (89 lb in).
  9. Ensure that the MAP sensor O-ring seal (3) is installed on the MAP sensor (2).
  10. Install the MAP sensor (2) and bolts (1) and tighten the bolts to 10 N.m (89 lb in).
    11. Fig 3: View Of Intake Manifold, Gasket & Bolts
    GM2032154Courtesy of GENERAL MOTORS CORP.
  11. Install a NEW intake manifold gasket.
  12. Install the intake manifold to the studs.
  13. Install the intake manifold nuts (1) and bolts (2) and tighten.
    • Tighten the bolts (2) to 25 N.m (18 lb ft).
    • Tighten the nuts (1) to 20 N.m (15 lb ft).
    14. Fig 4: Identifying fuel pump bracket & A/C pipe bracket bolts
    GM2074201Courtesy of GENERAL MOTORS CORP.
  14. Install the fuel pump bracket bolt (1) and tighten to 10 N.m (89 lb in).
  15. Install the A/C pipe bracket bolt (2) and tighten to 10 N.m (89 lb in).
    16. Fig 5: Intake Manifold Brace
    GM1825528Courtesy of GENERAL MOTORS CORP.
  16. Install the intake manifold brace.
  17. Loosely install the intake manifold brace bolt.
  18. Tighten the intake manifold brace bolt and tighten to 22 N.m (16 lb ft).
  19. Install the charge air bypass valve vacuum tank. Refer to Charge Air Bypass Valve Vacuum Tank Replacement .
    20. Fig 6: Fuel Feed Pipe & Bolts
    GM1825534Courtesy of GENERAL MOTORS CORP.
  20. Lubricate the high pressure fuel pump fuel feed pipe connection threads with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent.
  21. Place the fuel feed pipe on top of the intake manifold.
  22. Connect the fuel feed pipe fitting to the high pressure fuel pump.
  23. Install the fuel feed pipe bolts.
    • Tighten the bolts to 10 N.m (89 lb in).
    • Tighten the fittings to 30 N.m (22 lb ft).
  24. Connect the metal quick connect fitting to the fuel feed pip. Refer to Metal Collar Quick Connect Fitting Service .
    25. Fig 7: Charge Air Bypass Valve Solenoid Assembly
    GM1825530Courtesy of GENERAL MOTORS CORP.
  25. Position the charge air bypass valve solenoid assembly to the intake manifold.
  26. Install the charge air bypass valve solenoid bolts and tighten to 10 N.m (89 lb in).
  27. Install the charge air bypass valve vacuum hose to the intake manifold.
  28. Position the charge air bypass valve vacuum hose clamp at the intake manifold.
    29. Fig 8: Identifying Surge Tank Air Bleed Hose
    GM2031935Courtesy of GENERAL MOTORS CORP.
  29. Position the surge tank air bleed hose to the engine.
    30. Fig 9: ETC Connector
    GM1825527Courtesy of GENERAL MOTORS CORP.
  30. Connect the engine wiring harness electrical connector (1) to the TAC module.
  31. Install the engine wiring harness clip (3) to the intake manifold brace.
    32. Fig 10: Locating Knock Sensor Electrical Connector
    GM2031491Courtesy of GENERAL MOTORS CORP.
  32. Install the knock sensor electrical connector (1) clip to the intake manifold brace.
    33. Fig 11: Brake Booster Hose
    GM1825523Courtesy of GENERAL MOTORS CORP.
  33. Install the brake booster hose to the intake manifold.
  34. Position the brake booster vacuum hose clamp at the intake manifold.
  35. Connect the EVAP line quick connect fitting (2) to the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service .
    36. Fig 12: Identifying Intake Manifold Vacuum Lines & Air Valve Solenoid Electrical Connectors
    GM2003695Courtesy of GENERAL MOTORS CORP.
  36. Connect the charge air valve solenoid vacuum electrical connector (2).
  37. Connect the charge air valve solenoid vacuum lines (1).
  38. Connect the fuel feed line quick connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  39. Install the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement .
  40. Install the charge air cooler outlet pipe to the throttle body. Refer to Charge Air Cooler Outlet Pipe Replacement .
  41. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
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