General Motors — Intake Manifold, Remove and Install

A General Motors service procedure — check it applies to your exact model before use.

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Procedure

1. Important: Fuel leak - observe safety regulations and national legislation. Reduce fuel pressure with Pressure Tester KM-J-34730-91 via testing port - collect escaping fuel in suitable container.
2. Remove, Disconnect: Disconnect ground cable from battery.
3. Open coolant drain bolt - collect escaping coolant. Drain cooling system.
4. Remove engine vent hoses from camshaft housing cover. Remove coolant hose from intake.
5. Remove air cleaner housing and air intake hose.
6. Remove fuel lines and harness from fuel injectors.
7. Remove intake manifold nuts.
8. Remove intake manifold and gasket.
9. Clean: Clean sealing surfaces and remove gasket remnants.
10. Install, Connect: Attach inlet manifold with new gasket to cylinder head - tightening torque 22 Nm / 16 lbf.ft.
11. Attach fuel lines.
12. Attach coolant hose to intake manifold.
13. Connect wiring harness plug to injectors.
14. Install air cleaner housing with air intake hose.
15. Attach engine vent hoses to camshaft housing cover.
16. Close coolant drain bolt. Connect ground cable to battery.
17. Refill cooling system and purge air from system.

Source: manual:PSI_Tier_2__1.6L_PFI_Certified_Engine_Service_Manual_PSI1P6LP.pdf. Figures and steps are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.