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Home >> Chevrolet >> 2016 >> Malibu LS >> Repair and Diagnosis >> External Pages >> Different car >> Section 10 (Engine Mechanical - 2.0L (LTG) Or 2.5L (LKW) - Repair Instructions - On Vehicle) >> Repair Instructions - On Vehicle >> Intake Manifold Replacement (LTG) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2015 Chevrolet Malibu. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the intake manifold gasket (1).
    Fig 1: Intake Manifold Gasket
    GM2815742Courtesy of GENERAL MOTORS COMPANY
    NOTE: When installing the intake manifold, ensure that the gasket seal is securely installed prior to positioning the intake manifold.
  2. Install the fuel injection fuel rail fuel pressure sensor. Refer to Fuel Injection Fuel Rail Fuel Pressure Sensor Replacement .
  3. Install the intake manifold (2).
    Fig 2: Intake Bolts
    GM2815536Courtesy of GENERAL MOTORS COMPANY
  4. Hand start the intake manifold bolts (1).
    NOTE: If tape has been installed to ease intake manifold removal, remove the tape.
  5. Tighten the bolts in sequence twice to 12 N.m (106 lb in).
    Fig 3: Intake Manifold Bolt Tightening Sequence
    GM2726735Courtesy of GENERAL MOTORS COMPANY
    CAUTION: Refer to Fastener Caution .
  6. Position the intake manifold cover (2) over the intake manifold then engage the clips (1) to secure the cover.
    Fig 4: Intake Manifold Cover And Clips
    GM3630698Courtesy of GENERAL MOTORS COMPANY
  7. Install the fuel pump. Refer to Fuel Pump Replacement .
  8. Install the throttle body. Refer to Throttle Body Assembly Replacement (LTG) .
  9. Install the EVAP Canister Purge Solenoid Valve (1).
    Fig 5: EVAP Canister Valve
    GM2726730Courtesy of GENERAL MOTORS COMPANY
  10. Install the power brake booster vacuum pipes. Refer to Power Brake Booster Vacuum Pipe Replacement (LTG, LKW) and Power Brake Booster Vacuum Rear Pipe Replacement (LTG) .
  11. Install the radiator surge tank inlet hose. Refer to Radiator Surge Tank Inlet Hose Replacement (LTG) .
  12. Install the PCV pipe (2). Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (LTG/Non Tamper Proof)  and Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (LTG/ Valve with Pipe Tamper Proof) .
    Fig 6: PCV Pipe
    GM2869540Courtesy of GENERAL MOTORS COMPANY
  13. Install the power brake booster vacuum pipes. Refer to Power Brake Booster Vacuum Pipe Replacement (LTG, LKW) and Power Brake Booster Vacuum Rear Pipe Replacement (LTG) .
  14. Install the charge air cooler outlet tube. Refer to Charge Air Cooler Outlet Air Tube Replacement (LTG) .
  15. Connect the fuel feed pipe. Refer to Fuel Feed Pipe Replacement (At Tank) and Fuel Feed Pipe Replacement (Engine to Chassis LTG) .
  16. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement (LTG) .
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