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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 >> Removal Procedure

Removal Procedure

WARNING: This page is about a different variant/trim than selected.
CAUTION: Never attempt to remove the intake manifold from a hot engine, allow the engine to cool to ambient temperature. The intake manifold can be damaged if it is removed when the engine is hot.
    Fig 1: Identifying EVAP & Fuel Feed Pipes
    GM1825535Courtesy of GENERAL MOTORS CORP.
  1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .
  2. Remove the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement .
  3. Disconnect the fuel feed line quick connect fitting (1) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  4. Disconnect the evaporative emission (EVAP) line quick connect fitting (2) from the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service .
    5. Fig 2: View Of Brake Booster Vacuum Hose
    GM1825523Courtesy of GENERAL MOTORS CORP.
  5. Reposition the brake booster vacuum hose clamp at the intake manifold.
  6. Remove the brake booster hose from the intake manifold.
    7. Fig 3: Identifying Front & Rear Knock Sensor Clips
    GM1717513Courtesy of GENERAL MOTORS CORP.
  7. Remove the knock sensor electrical connector (1) clip from the intake manifold brace.
  8. Remove the knock sensor electrical connector (2) clip from the oil level indicator tube bracket.
    9. Fig 4: Identifying MAP Sensor Connector
    GM1825525Courtesy of GENERAL MOTORS CORP.
  9. Disconnect the engine wiring harness electrical connector (1) from the EVAP canister purge solenoid.
  10. Disconnect the engine wiring harness electrical connector (2) from the manifold absolute pressure (MAP) sensor.
  11. Disconnect the engine wiring harness electrical connector from the charge air bypass vale solenoid.
    12. Fig 5: Identifying Throttle Actuator & Knock Sensor Electrical Connectors & Harness Clip
    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 Hose Components
    GM1825533Courtesy of GENERAL MOTORS CORP.
  14. Reposition the surge tank air bleed hose clamp at the engine (1).
  15. Remove the surge tank air bleed hose from the engine.
  16. Remove the surge tank air bleed hose clip (2) from the surge tank bracket.
  17. Reposition the surge tank air bleed hose out of the way.
    18. Fig 7: Identifying Charge Air Bypass Valve Solenoid Assembly
    GM1825530Courtesy of GENERAL MOTORS CORP.
  18. Reposition the charge air bypass valve vacuum hose clamp at the intake manifold.
  19. Remove the charge air bypass valve vacuum hose from the intake manifold.
  20. Remove the charge air bypass valve solenoid bolts.
  21. Reposition the charge air bypass valve solenoid assembly out of the way.
    22. Fig 8: Identifying Surge Tank Bracket
    GM1825532Courtesy of GENERAL MOTORS CORP.
  22. Remove the surge tank bracket bolt (1) and stud (2).
  23. Remove the surge tank bracket (3).
  24. Remove the surge tank hose retainer and hose from the surge tank bracket.
    25. Fig 9: Identifying Fuel Feed Pipe & Bolts
    GM1825534Courtesy of GENERAL MOTORS CORP.
  25. Disconnect the metal quick connect fitting from the fuel feed pip. Refer to Metal Collar Quick Connect Fitting Service .
  26. Disconnect the fuel feed pipe fitting from the fuel pump.
  27. Remove the fuel feed pipe bolts.
  28. Remove the fuel feed pipe.
  29. Inspect the fuel feed pipe nut for damaged threads.
  30. Inspect the fuel feed pipe sealing bail for damage or debris.
  31. Replace the fuel feed pipe if any damage is found.
    32. Fig 10: View Of Intake Manifold Brace
    GM1825528Courtesy of GENERAL MOTORS CORP.
  32. Remove the intake manifold brace bolt.
  33. Remove the intake manifold brace.
    34. Fig 11: View Of Intake Manifold
    GM1825531Courtesy of GENERAL MOTORS CORP.
  34. Remove the intake manifold bolts and nuts.
  35. Remove the intake manifold and place on a clean work surface.
    36. NOTE: The intake manifold gasket is reusable. Only replace the gasket if damage has occurred.
  36. Remove the intake manifold gasket, if necessary.
    37. Fig 12: View Of EVAP Canister Purge Solenoid
    GM1825560Courtesy of GENERAL MOTORS CORP.
  37. If replacing the intake manifold perform the following steps, otherwise proceed to step 11 in the installation procedure.
  38. Remove the MAP sensor bolts (1).
  39. 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.
  40. Remove the EVAP purge solenoid bolt (6).
  41. 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.
    42. Fig 13: View Of Throttle Body
    GM1825561Courtesy of GENERAL MOTORS CORP.
  42. Turn the intake manifold up side down.
  43. Remove the throttle body bolts.
  44. Remove the throttle body and seal.
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