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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) >> Removal Procedure

Removal 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. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement (LTG) .
  2. Remove the charge air cooler outlet tube. Refer to Charge Air Cooler Outlet Air Tube Replacement (LTG) .
  3. Disconnect the fuel feed pipe. Refer to Fuel Feed Pipe Replacement (At Tank) and Fuel Feed Pipe Replacement (Engine to Chassis LTG) .
  4. Remove 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 1: PCV Pipe
    GM2869540Courtesy of GENERAL MOTORS COMPANY
  5. Remove 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) .
  6. Remove the radiator surge tank inlet hose. Refer to Radiator Surge Tank Inlet Hose Replacement (LTG) .
  7. Remove the EVAP Canister Purge Solenoid Valve. (1).
    Fig 2: EVAP Canister Valve
    GM2726730Courtesy of GENERAL MOTORS COMPANY
  8. Remove the throttle body. Refer to Throttle Body Assembly Replacement (LTG) .
  9. Remove the fuel pump. Refer to Fuel Pump Replacement .
  10. Disengage the intake manifold cover clips (1) then remove the cover (2).
    Fig 3: Intake Manifold Cover And Clips
    GM3630698Courtesy of GENERAL MOTORS COMPANY
  11. Fully loosen the intake manifold bolts (1) in order to remove the intake manifold.
    Fig 4: Intake Bolts
    GM2815536Courtesy of GENERAL MOTORS COMPANY
    NOTE: The intake manifold bolts are retained in the intake manifold. If the bolts cause clearance concerns, secure them as needed using a suitable.
  12. Separate the intake manifold from the engine to gain access to the fuel pressure sensor.
    NOTE: The fuel injection fuel rail fuel pressure sensor must be removed to obtain enough clearance to remove the intake manifold from the vehicle.
  13. Remove the fuel injection fuel rail fuel pressure sensor. Refer to Fuel Injection Fuel Rail Fuel Pressure Sensor Replacement .
  14. Remove the intake manifold (2) from the vehicle.
  15. Remove the intake manifold gasket (1) and DISCARD.
    Fig 5: Intake Manifold Gasket
    GM2815742Courtesy of GENERAL MOTORS COMPANY
  16. For intake manifold cleaning and inspection. Refer to Intake Manifold Cleaning and Inspection .
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