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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 >> Removal Procedure

Removal 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: Identifying Intake Manifold Vacuum Lines & Air Valve Solenoid Electrical Connectors
    GM2003695Courtesy of GENERAL MOTORS CORP.
  1. Disconnect the charge air cooler outlet pipe from the throttle body. Refer to Charge Air Cooler Outlet Pipe Replacement .
  2. Remove the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement .
  3. Disconnect the fuel feed line quick connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  4. Disconnect the charge air valve solenoid vacuum lines (1).

    Mark the lines to ease installation.

  5. Disconnect the charge air valve solenoid vacuum electrical connector (2).
    6. Fig 2: Locating EVAP Line Connector & MAP Sensor Electrical Connector
    GM2003725Courtesy of GENERAL MOTORS CORP.
  6. Disconnect the evaporative emission (EVAP) electrical connector (1) from the EVAP purge solenoid.
  7. Disconnect the evaporative emission (EVAP) line quick connect fitting (2) from the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service .
  8. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (3).
    9. Fig 3: Brake Booster Hose
    GM1825523Courtesy of GENERAL MOTORS CORP.
  9. Reposition the brake booster vacuum hose clamp at the intake manifold.
  10. Remove the brake booster hose from the intake manifold.
    11. Fig 4: Locating Knock Sensor Electrical Connector
    GM2031491Courtesy of GENERAL MOTORS CORP.
  11. Remove the knock sensor electrical connector (1) clip from the intake manifold brace.
    12. Fig 5: ETC Connector
    GM1825527Courtesy of GENERAL MOTORS CORP.
  12. Disconnect the engine wiring harness electrical connector (1) from the throttle actuator control (TAC) module.
  13. Remove the engine wiring harness clip (3) from the intake manifold brace.
    14. Fig 6: Identifying Surge Tank Air Bleed Hose
    GM2031935Courtesy of GENERAL MOTORS CORP.
  14. Reposition the surge tank air bleed hose clamp at the engine (1).
  15. Reposition the surge tank air bleed hose out of the way.
    16. Fig 7: Charge Air Bypass Valve Solenoid Assembly
    GM1825530Courtesy of GENERAL MOTORS CORP.
  16. Reposition the charge air bypass valve vacuum hose clamp at the intake manifold.
  17. Remove the charge air bypass valve vacuum hose from the intake manifold.
  18. Remove the charge air bypass valve solenoid bolts.
  19. Reposition the charge air bypass valve solenoid assembly out of the way.
    20. Fig 8: Fuel Feed Pipe & Bolts
    GM1825534Courtesy of GENERAL MOTORS CORP.
  20. Disconnect the metal quick connect fitting from the fuel feed pipe. Refer to Metal Collar Quick Connect Fitting Service .
  21. Disconnect the fuel feed pipe fitting from the fuel pump.
  22. Remove the fuel feed pipe bolts.
  23. Remove the fuel feed pipe.
  24. Inspect the fuel feed pipe nut for damaged threads.
  25. Inspect the fuel feed pipe sealing bail for damage or debris.
  26. Replace the fuel feed pipe if any damage is found.
  27. Remove the charge air bypass valve vacuum tank. Refer to Charge Air Bypass Valve Vacuum Tank Replacement .
    28. Fig 9: Intake Manifold Brace
    GM1825528Courtesy of GENERAL MOTORS CORP.
  28. Remove the intake manifold brace bolt.
  29. Remove the intake manifold brace.
    30. Fig 10: Identifying fuel pump bracket & A/C pipe bracket bolts
    GM2074201Courtesy of GENERAL MOTORS CORP.
  30. Remove the fuel pump bracket bolt (1).
  31. Remove the A/C pipe bracket bolt (2) and reposition the bracket.
    32. Fig 11: View Of Intake Manifold, Gasket & Bolts
    GM2032154Courtesy of GENERAL MOTORS CORP.
  32. Remove the intake manifold nuts (1) and bolts (2).
  33. Remove the intake manifold and place on a clean work surface.
  34. Remove the intake manifold gasket and discard.
    35. Fig 12: EVAP Canister Purge Solenoid
    GM1825560Courtesy of GENERAL MOTORS CORP.
  35. If replacing the intake manifold perform the following steps, otherwise proceed to step 11 in the installation procedure.
  36. Remove the MAP sensor bolts (1).
  37. Remove the MAP sensor (2), ensure that the O-ring seal (3) is still attached on the sensor, if not remove the O-ring seal from the intake manifold.
  38. Remove the EVAP purge solenoid bolt (6).
  39. Remove the EVAP purge solenoid (5), ensure that the O-ring seal (4) is still attached on the sensor, if not remove the O-ring seal from the intake manifold.
    40. Fig 13: Throttle Body
    GM1825561Courtesy of GENERAL MOTORS CORP.
  40. Turn the intake manifold up side down.
  41. Remove the throttle body bolts.
  42. Remove the throttle body and seal.
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