Corvette 2005-2008

Intake Manifold

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Engine sight covers
     
    Fuel injector electrical connectors
     
    Throttle body electrical connectors
     
    Fuel supply line for the fuel injectors
     
    Fuel rail
     
    Brake booster vacuum hose
     
    Manifold absolute pressure (MAP) sensor
     
    Evaporative emission (EVAP) valve and tube assembly from the intake manifold assembly
     
    Intake manifold mounting bolts and fuel rail stop bracket
     
    Intake manifold and gaskets
     

  8.  

To install:


WARNING
Do not reuse the intake manifold gaskets.

  1. Install new intake manifold gaskets.
  2.  
  3. Install the intake manifold.
  4.  
  5. Install the fuel rail stop bracket.
  6.  
  7. Apply a 5 mm (0.2 inch) band of threadlocker to the threads of the intake manifold bolts
  8.  
  9. Install the intake manifold bolts and tighten in sequence as follows:
    1. Step 1: Tighten to 44 inch lbs. (5 Nm).
    2.  
    3. Step 2: Tighten to 89 inch lbs. (10 Nm).

      Click image to see an enlarged view

      Fig. Intake manifold torque sequence

    4.  

  10.  
  11. Install or connect the following:

    MAP sensor
     
    EVAP valve and tube assembly to the intake assembly. Tighten the mounting bolt to 37 ft. lbs. (50 Nm)
     
    Install the EVAP tubes
     
    Fuel rail and fuel supply hose
     
    Brake booster vacuum hose
     
    Throttle body electrical connectors
     
    Fuel injector electrical connectors
     
    Engine sight covers
     
    Negative battery cable
     

  12.  
  13. Refill the cooling system to the correct level.
  14.  
  15. Start the engine and check for leaks.
  16.  

 
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