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Home >> Pontiac >> 2010 >> Solstice Base, 2D Convertible, Standard >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 3 (Engine Mechanical - 2.0L - Repair Instructions - On Vehicle) >> Intake Manifold Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different variant/trim than selected.
    Fig 1: View Of 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.

    Tighten:  Tighten the bolts to 10 N.m (89 lb in).

  5. Turn the intake manifold right side up.
    6. Fig 2: View Of 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).

    Tighten:  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).

    Tighten:  Tighten the bolts to 10 N.m (89 lb in).

    11. Fig 3: View Of Intake Manifold
    GM1825531Courtesy of GENERAL MOTORS CORP.
  11. Install the intake manifold gasket, if necessary.
  12. Install the intake manifold to the studs.
  13. Install the intake manifold bolts and nuts.

    Tighten:  Tighten the bolts/nuts to 22 N.m (16 lb ft).

    14. Fig 4: View Of Intake Manifold Brace
    GM1825528Courtesy of GENERAL MOTORS CORP.
  14. Install the intake manifold brace.
  15. Loosely install the intake manifold brace bolt.
  16. Tighten the intake manifold brace bolt.

    Tighten:  Tighten the bolt to 22 N.m (16 lb ft).

    17. Fig 5: Identifying Fuel Feed Pipe & Bolts
    GM1825534Courtesy of GENERAL MOTORS CORP.
  17. Lubricate the high pressure fuel pump fuel feed pipe connection threads with silicon free engine oil. Refer to Adhesives, Fluids, Lubricants, and Sealers for the recommended lubricant.
  18. Place the fuel feed pipe on top of the intake manifold.
  19. Connect the fuel feed pipe fitting to the high pressure fuel pump.
  20. Install the fuel feed pipe bolts.

    Tighten: 

    • Tighten the bolts to 10 N.m (89 lb in).
    • Tighten the fitting to 30 N.m (22 lb ft).

  21. Connect the metal quick connect fitting to the fuel feed pip. Refer to Metal Collar Quick Connect Fitting Service .
    22. Fig 6: Identifying Surge Tank Bracket
    GM1825532Courtesy of GENERAL MOTORS CORP.
  22. Position the surge tank bracket (3) to the intake manifold.
  23. Install the surge tank bracket bolt (1) and stud (2).

    Tighten:  Tighten the bolt/stud to 9 N.m (80 lb in).

  24. Install the surge tank hose retainer and hose to the surge tank bracket.
    25. Fig 7: Identifying 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.

    Tighten:  Tighten the bolts 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 Hose Components
    GM1825533Courtesy of GENERAL MOTORS CORP.
  29. Position the surge tank air bleed hose to the engine.
  30. Install the surge tank air bleed hose to the engine.
  31. Position the surge tank air bleed hose clamp at the engine (1).
  32. Install the surge tank air bleed hose clip (2) to the surge tank bracket.
    33. Fig 9: Identifying Throttle Actuator & Knock Sensor Electrical Connectors & Harness Clip
    GM1825527Courtesy of GENERAL MOTORS CORP.
  33. Connect the engine wiring harness electrical connector (1) to the TAC module.
  34. Install the engine wiring harness clip (3) to the intake manifold brace.
    35. Fig 10: Identifying MAP Sensor Connector
    GM1825525Courtesy of GENERAL MOTORS CORP.
  35. Connect the engine wiring harness electrical connector to the charge air bypass vale solenoid.
  36. Connect the engine wiring harness electrical connector (2) to the MAP sensor.
  37. Connect the engine wiring harness electrical connector (1) to the EVAP canister purge solenoid.
    38. Fig 11: Identifying Front & Rear Knock Sensor Clips
    GM1717513Courtesy of GENERAL MOTORS CORP.
  38. Install the knock sensor electrical connector (1) clip to the intake manifold brace.
  39. Install the knock sensor electrical connector (2) clip to the oil level indicator tube bracket.
    40. Fig 12: View Of Brake Booster Vacuum Hose
    GM1825523Courtesy of GENERAL MOTORS CORP.
  40. Install the brake booster hose to the intake manifold.
  41. Position the brake booster vacuum hose clamp at the intake manifold.
    42. Fig 13: Identifying EVAP & Fuel Feed Pipes
    GM1825535Courtesy of GENERAL MOTORS CORP.
  42. Connect the EVAP line quick connect fitting (2) to the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service .
  43. Connect the fuel feed line quick connect fitting (1) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  44. Install the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement .
  45. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .
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