Cavalier, Sunfire 2001-2005

Intake Manifold

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Removal & Installation



2.2L (VIN 4) Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Air cleaner inlet duct
     
    Air inlet resonator and bracket
     
    Throttle and cruise control cable from the throttle body
     
    Manifold Absolute Pressure (MAP) sensor
     
    Throttle Position (TPS) sensor
     
    Idle Air Control (IAC) valve
     
    Fuel supply line
     
    Throttle body
     
    Fuel inlet pipe
     
    Intake manifold
     

  6.  

To install:

Click image to see an enlarged view

Fig. Intake manifold tightening sequence-2.2L (Vin 4) engine

  1. Install or connect the following:

    Intake manifold with a new gasket. Torque the bolts/nuts, in sequence, to 18 ft. lbs. (24 Nm).
     
    Fuel inlet pipe. Torque the bolts to 18 ft. lbs. (24 Nm).
     
    Throttle body. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Fuel supply line
     
    MAP sensor
     
    TPS sensor
     
    IAC valve
     
    Cruise control and throttle cables to the throttle body
     
    Air inlet resonator bracket and resonator
     
    Air cleaner inlet duct
     
    Negative battery cable
     

  2.  

These vehicles were filled at the factory with an antifreeze/coolant called GM Goodwrench DEX-COOL®. When adding coolant to vehicles, it is important that you use GM Goodwrench DEX-COOL® (orange-colored, silicate-free) coolant. Propylene glycol is not recommended for use in GM vehicles . A 50/50 mixture of DEX-COOL® and clean water will provide all the recommended protection. DO NOT mix DEX-COOL® with any other type of antifreeze .

2.2L (VIN F) Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Air inlet duct and resonator
     
    Idle Air Control (IAC) electrical connector
     
    Throttle Position (TP) sensor electrical connector
     
    Manifold Absolute Pressure (MAP) sensor electrical connector
     
    Evaporative Emissions (EVAP) hose
     
    Positive Crankcase Ventilation (PCV) hose
     
    Purge solenoid tube
     
    Brake booster hose
     
    Oil level indicator tube bolt
     
    Accelerator and cruise control cables
     
    Throttle body
     
    Fuel rail
     
    Knock Sensor (KS) connector from the intake manifold
     
    Intake manifold nuts and bolts
     
    Intake manifold and gasket. The gasket is reusable if the gasket is not damaged.

    Click image to see an enlarged view

    Fig. Remove the throttle body-2.2L (VIN F) engine



    Click image to see an enlarged view

    Fig. Remove the intake manifold-2.2L (VIN F) engine

     

  4.  

To install:

  1. Install or connect the following:

    Intake manifold gasket
     
    Intake manifold
     
    Intake manifold nuts and bolts and tighten to 89 inch lbs. (10 Nm)
     
    KS connector
     
    Fuel rail
     
    Throttle body
     
    IAC, TP, and MAP electrical connectors
     
    EVAP hose
     
    PCV hose
     
    Purge solenoid tube
     
    Brake booster hose
     
    Oil level indicator tube bolt
     
    Accelerator and the cruise control cables
     
    Air inlet duct and resonator
     

  2.  

 
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