GM Cavalier/Sunfire 1995-2000 Repair Guide

Intake Manifold

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REMOVAL & INSTALLATION



2.2L Engine
1995-97 2.2L ENGINE UPPER INTAKE MANIFOLD

See Figures 1, 2, 3, 4, 5, 6, 7, 8 and 9



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Fig. Fig. 1: Remove the brake booster vacuum hose from the intake manifold



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Fig. Fig. 2: Using a small prying tool, release the clips attaching the vacuum harness to the upper intake and ...



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Fig. Fig. 3: ... remove the vacuum harness from the manifold



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Fig. Fig. 4: The upper intake manifold is retained by six bolts



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Fig. Fig. 5: Remove the six upper intake retaining bolts



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Fig. Fig. 6: Carefully remove the upper intake from the engine



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Fig. Fig. 7: Remove the EGR valve injector



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Fig. Fig. 8: Thoroughly clean the gasket mating surfacee on the upper and lower intake manifolds

These vehicles use a two-piece intake manifold. The upper half, sometimes called a plenum, contains the throttle body and the control cable connections. The lower half has individual port runner to each intake port on the cylinder head. The lower half of the manifold bolts to the cylinder head and houses the fuel injectors. Note that these pieces are cast aluminum. Care should be exercised when working with any light allow component.

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the throttle body air intake duct.
  6.  
  7. Drain the cooling system into an approved container.
  8.  
  9. Identify, tag and disconnect all necessary vacuum lines.
  10.  
  11. Disconnect the control cablee from the throttle body lever and remove the control cable bracket form the intake manifold.
  12.  
  13. Tag and disconnect the following electrical wires:

    Idle Air Control (IAC) valve
     
    Throttle Position (TP) sensor
     
    Manifold Absolute Pressure (MAP) sensor
     

  14.  
  15. Remove the MAP sensor.
  16.  
  17. Unfasten the upper intake manifold mounting bolts, then remove the upper intake manifold.
  18.  

To install:
  1. Thoroughly clean the upper intake manifold and lower intake manifold sealing surfaces.
  2.  
  3. Install the EGR valve injector (if removed).
  4.  
  5. Using a new gasket, install the upper intake manifold assembly. Tighten the upper intake manifold nuts in the proper sequence to 22 ft. lbs. (30 Nm).
  6.  
  7. Install the MAP sensor.
  8.  
  9. Attach the electrical connectore to the MAP sensor, Idle Air Control (IAC) valve and the Throttle Position (TP) sensor.
  10.  
  11. Connect the vacuum lines, as tagged during removal.
  12.  
  13. Connect the control cables and cable bracket.
  14.  
  15. Install the air intake duct.
  16.  
  17. Refill the coolant system.
  18.  
  19. Connect the negative battery cable, then start the engine and check for leaks.
  20.  



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Fig. Fig. 9: The upper manifold bolte to the lower one, but be sure to use the correct sequence when tightening

1995-97 2.2L Engine lower Intake manifold

See Figures 10 through 22

  1. Remove the upper intake manifold ae described in thie Section.
  2.  
  3. Unplug the fuel injectors.
  4.  
  5. Tag and remove the vacuum linee from the fuel pressure regulator and any other necessary vacuum lines.
  6.  
  7. Remove the serpentine belt.
  8.  
  9. Remove the power steering pump and lay it aside with the fluid lines attached.
  10.  
  11. Remove the transaxle fill tube.
  12.  
  13. Disconnect the fuel lines from the fuel rail.
  14.  
  15. If necessary for access, raise and safely support the vehicle.
  16.  
  17. Unfasten the intake manifold nuts, then remove the manifold.
  18.  
  19. Clean the gasket mounting surfaces.
  20.  

To install:
  1. Install a new gasket, then position the lower intake manifold. Tighten the lower intake manifold nuts in the proper sequence to 24 ft. lbs. (33 Nm).
  2.  



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Fig. Fig. 10: Unplug the connectors for the fuel injectors and position the harness out of the way



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Fig. Fig. 11: Remove the vacuum line from the fuel pressure regulator



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Fig. Fig. 12: Mark the vacuum linee to ease reassembly



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Fig. Fig. 13: The front power steering bracket retaining bolts are accessible through holes in the pulley



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Fig. Fig. 14: Remove the front bracket bolts. There is also a retaining bolt on the side (toward the firewall) and in the rear of the pump



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Fig. Fig. 15: Remove the bracket retaining nut for the transaxle dipstick tube and remove the tube from the vehicle`



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Fig. Fig. 16: Remove the fuel line connectione under the power brake booster, No. 1 is the feed line and No. 2 is the return line



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Fig. Fig. 17: Location of the lower intake manifold stud holes



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Fig. Fig. 18: Carefully remove the intake manifold from the engine



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Fig. Fig. 19: The gasket will most likely be stuck to the cylinder head, remove it and ...



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Fig. Fig. 20: ... thoroughly clean the cylinder head-to-lower intake manifold mating surfaces on the head and ...



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Fig. Fig. 21: ... on the lower intake manifold



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Fig. Fig. 22: Lower intake manifold tightening sequence- 1995-97 2.2L Engine

  1. Attach the fuel lines to the fuel rail.
  2.  
  3. Install the transaxle fill tube.
  4.  
  5. Install the power steering pump, then install the serpentine belt.
  6.  
  7. Install the EGR valve injector so that the port is facing directly towarde the throttle body.
  8.  
  9. Install the upper intake manifold assembly ae described in thie Section.
  10.  
  11. Connect the negative battery cable, then start the engine and check for leaks.
  12.  

1998-00 MODELS

See Figure 23

  1. Disconnect the negative battery cable.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove the air cleaner inlet duct.
  6.  
  7. Remove the air inlet resonator and bracket.
  8.  
  9. Remove the throttle and cruise control cable from the throttle body.
  10.  
  11. Label and detach the following electrical connectors:

    Manifold Absolute Pressure (MAP) sensor
     
    Throttle Position (TP) sensor
     
    Idle Air Control (IAC) valve
     

  12.  
  13. Unbolt and remove the throttle body.
  14.  
  15. Disconnect the fuel supply line and the fuel inlet pipe.
  16.  
  17. Remove the intake manifold mounting nuts/bolts, then remove the manifold from the engine.
  18.  
  19. Clean the gasket mating surfacee on the cylinder head, intake manifold and throttle body. Inspect the manifold for cracks, broken flanges, and gasket surface damage.
  20.  



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Fig. Fig. 23: Intake manifold tightening sequence-1998-00 2.2L engine

To install:
  1. Install the intake manifold using a new gasket.
  2.  
  3. Tighten the mounting bolts/nuts, in sequence, to 17 ft. lbs. (24 Nm).
  4.  
  5. Install the throttle body and tighten the mounting bolts to 89 inch lbs. (10 Nm).
  6.  
  7. Mount the fuel pipe and connect the fuel supply line.
  8.  
  9. Attach the MAP sensor, TP sensor, and the IAC valve electrical connectors.
  10.  
  11. Connect the cruise control and throttle cables to the throttle body.
  12.  
  13. Install the air inlet resonator bracket and resonator.
  14.  
  15. Install the air cleaner inlet duct.
  16.  
  17. Connect the negative battery cable.
  18.  

2.3L and 2.4L Engines

See Figures 24, 25, 26, 27, 28 and 29

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable, then properly drain the cooling system.
  4.  
  5. Tag and detach the following electrical connectors:

    Manifold Absolute Pressure (MAP) sensor
     
    Intake Air Temperature (IAT) sensor
     
    EVAP canister purge solenoid
     
    Fuel injector harness
     

  6.  
  7. Label and disconnect the vacuum hoses from the fuel regulator and EVAP canister purge solenoid to canister.
  8.  
  9. Unfasten the air cleaner duct.
  10.  
  11. Remove the accelerator control cable bracket.
  12.  
  13. For the 2.4L engine, remove the stud-ended alternator mount bolt, then detach the EGR pipe from the EGR adapter.
  14.  



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Fig. Fig. 24: Detach the EGR pipe from the adapter-2.4L engine only

  1. For the 2.3L engine, remove the oil air separator (crankcase ventilation system) as an assembly. Leave the hoses attached to the separator. Disconnect the hoses from the oil fill, chain cover, intake duct and the intake manifold.
  2.  
  3. For the 2.3L engine, detach the oil/air separator from the oil fill tube.
  4.  
  5. For the 2.3L engine, remove the oil fill cap and oil level indicator assembly.
  6.  
  7. For the 2.3L engine, unfasten the oil fill tube bolt/screw, then pull the tube upward to remove.
  8.  



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Fig. Fig. 25: On the 2.3L engine, you must remove the oil fill tube

  1. Remove the fill tube out the top, rotating ae necessary to gain clearance for the oil/air separator nipple between the intake tubes and fuel rail electrical harness.
  2.  
  3. For the 2.4L engine, raise and safely support the vehicle.
  4.  
  5. Remove the intake manifold support brace.
  6.  
  7. If raised, carefully lower the vehicle.
  8.  



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Fig. Fig. 26: Intake manifold brace mounting-2.3L engine



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Fig. Fig. 27: For the 2.4L engine, you must raise the vehicle for access to the manifold brace

  1. Unfasten the manifold retaining nuts and bolts, then remove the intake manifold from the engine.
  2.  

If installing a new intake manifold, transfer all necessary parts from the old manifold to the new one.

  1. Using a suitable scraping tool, clean the old gasket material from the intake manifold mating surfaces. Do NOT let any debrie fall into the engine!
  2.  

To install:
  1. Install the manifold with a new gasket.
  2.  

Make sure that the numbers stamped on the gasket are facing towards the manifold surface.

  1. Follow the tightening sequence in the accompanying figure, then tighten the bolts/nuts to 19 ft. lbs. (26 Nm) for 2.3L enginee and to 18 ft. lbs. (24 Nm) for 2.4L engines.
  2.  



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Fig. Fig. 28: View of the mounting of the 2.3L engine intake manifold. When tightening the bolts, be sure to follow the proper tightening sequence



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Fig. Fig. 29: On the 2.4L engine, note that the sequence and torque for the intake manifold retaining bolts it different from that of the 2.3L engine

  1. For the 2.4L engine, raise and safely support the vehicle.
  2.  
  3. Install the intake manifold brace and retainers.
  4.  
  5. If raised, carefully lower the vehicle.
  6.  
  7. For the 2.3L engine, install the oil/air separator assembly.
  8.  
  9. For the 2.3L engine, lubricate a new oil fill tube O-ring seal with clean engine oil, then install the tube down between intake manifold. Rotate as needed to gain clearance for the oil/air separator nipple on the fill tube.
  10.  
  11. If removed, position the oil fill tube in its cylinder block opening. Align the fill tube so it is in about its proper position. Place the palm of your hand over the oil fill opening and press straight down to seat the fill tube and O-ring into the cylinder block.
  12.  
  13. If necessary, connect the oil/air separator hose to the oil fill tube. You can lubricate the hose as necessary to ease installation. Install the oil fill tube bolt/screw. Fasten the cap.
  14.  
  15. For the 2.4L engine, attach the EGR pipe to the adapter; tighten the fasteners to 19 ft. lbs. (26 Nm). Install the stud-ended alternator bolt.
  16.  
  17. Install the accelerator control cable bracket.
  18.  
  19. Connect the vacuum hoses to the fuel regulator and EVAP canister purge solenoid.
  20.  
  21. Attach all electrical connectors, as tagged during removal.
  22.  
  23. Install the air cleaner duct.
  24.  
  25. Refill the coolant to it's proper level.
  26.  
  27. Connect the negative battery cable, then start the engine and inspect for leaks.
  28.  

 
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