Aveo 2004-2005

Intake Manifold

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Removal & Installation



  1. Relieve the fuel system pressure.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Coolant
     
    Electronic Control Module (ECM) ground terminal from intake manifold
     
    Air cleaner housing
     
    Throttle body
     
    Throttle cable
     
    Radiator hoses
     
    Intake manifold pressure sensor
     
    Intake Air Temperature (IAT) sensor
     
    Coolant temperature sensor
     
    Fuel feed line from fuel rail
     
    EGR pipe
     
    Alternator
     
    Intake manifold support bracket
     
    Intake manifold vacuum hoses
     
    Intake manifold retaining bolts and in the sequence shown. See Figure 4.

    Click image to see an enlarged view

    Fig. Intake manifold bolt removal sequence-1.6L engine



    Click image to see an enlarged view

    Fig. Intake manifold bolt tightening sequence-1.6L engine

     

  4.  

To install:

  1. Install or connect the following:

    Intake manifold with new gasket. Tighten the retainers in sequence to 18 ft. lbs. (25 Nm). See Figure 5.
     
    Fuel rail. Tighten the bolts to 18 ft. lbs. (25 Nm).
     
    EGR pipe
     
    Intake manifold support bracket. Tighten the upper bolts to 18 ft. lbs. (25 Nm) and the lower bolts to 33 ft. lb. (45 Nm).
     
    Alternator
     
    Intake manifold vacuum hoses
     
    IAT sensor
     
    Intake manifold pressure sensor
     
    Radiator hoses
     
    Throttle cable
     
    Throttle body
     
    Air cleaner housing
     
    ECM ground terminal from intake manifold
     
    Negative battery cable
     

  2.  
  3. Fill the engine with coolant.
  4.  
  5. Start the engine and check for leaks.
  6.  

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system.
  6.  
  7. Disconnect the intake air temperature (IAT) sensor connector.
  8.  
  9. Disconnect the air intake assembly from the throttle body.
  10.  
  11. Disconnect the idle air control (IAC) valve connector and throttle position sensor (TPS) connector.
  12.  
  13. Remove the alternator adjusting bolt and the accessory drive belt.
  14.  
  15. Disconnect the engine coolant temperature (ECT) sensor connector.
  16.  
  17. Disconnect the heater inlet hose from the cylinder head.
  18.  
  19. Disconnect the surge tank coolant hose at the throttle body.
  20.  
  21. Disconnect all of the necessary vacuum hoses, including the vacuum hose at the fuel pressure regulator and the brake boaster vacuum hose at the intake manifold.
  22.  
  23. Disconnect the throttle body cable from the throttle body and the intake manifold.
  24.  
  25. Remove the fuel injector rail and fuel injectors as an assembly.
  26.  
  27. Remove the alternator adjusting bracket bolt from the intake manifold and remove the alternator adjusting bracket.
  28.  
  29. Remove the intake manifold support bracket bolts and the intake manifold support bracket.
  30.  
  31. Remove the intake manifold retaining nuts/bolts in the sequence shown.
  32.  
  33. Remove the intake manifold and gasket.

    Click image to see an enlarged view

    Fig. Intake manifold bolt removal sequence-1.6L engine

  34.  

To install:

  1. Clean the sealing surfaces of the intake manifold and the cylinder head.
  2.  
  3. Install the intake manifold with a new gasket. Tighten the retaining nuts/bolts in the sequence shown to 18 ft. lbs. (25 Nm).

    Click image to see an enlarged view

    Fig. Intake manifold bolt tightening sequence-1.6L engine

  4.  
  5. Install the intake manifold support bracket and tighten the bracket bolts to 18 ft. lbs. (25 Nm).
  6.  
  7. Install the intake manifold support bracket lower bolt-to-engine block.
  8.  
  9. Install the fuel rail and fuel injectors as an assembly.
  10.  
  11. Connect the throttle cable to the intake manifold and the throttle body.
  12.  
  13. Connect all of the necessary vacuum lines that were previously disconnected.
  14.  
  15. Connect the heater inlet hose to the cylinder head.
  16.  
  17. Connect the surge tank coolant hose to the throttle body.
  18.  
  19. Install the alternator adjusting bracket at the intake manifold and tighten the bracket bolts to 11 ft. lbs. (15 Nm).
  20.  
  21. Install the alternator adjusting bolt and the accessory drive belt.
  22.  
  23. Connect the ECT sensor connector, IAC valve connector and TPS connector.
  24.  
  25. Connect the air intake assembly to the throttle body.
  26.  
  27. Connect the IAT sensor connector.
  28.  
  29. Connect the powertrain control module (PCM)/engine control module (ECM) ground terminal to the intake manifold.
  30.  
  31. Reinstall the fuel pump fuse.
  32.  
  33. Connect the negative battery cable.
  34.  
  35. Refill the cooling system to the correct level.
  36.  
  37. Start the engine and check for leaks.
  38.  

 
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