GM Corsica/Beretta 1988-1996 Repair Guide

Intake Manifold

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REMOVAL & INSTALLATION




CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

2.0L and 2.2L Engine
1988-99 VEHICLES

See Figure 1

  1. Properly relieve the fuel system pressure, as outlined in Fuel System of this guide.
  2.  
  3. If not already done, disconnect the negative battery cable.
  4.  
  5. Place a suitable container under the radiator, then drain the cooling system.
  6.  
  7. Remove the air cleaner assembly.
  8.  
  9. Tag and disconnect all necessary vacuum lines and wires.
  10.  
  11. Disconnect the fuel lines at the TBI unit. Disconnect the TBI linkage, then remove the TBI unit.
  12.  
  13. Remove the serpentine drive belt.
  14.  
  15. Remove the power steering pump-to-bracket bolts, then position the pump out of the way; DO NOT disconnect the pressure hoses.
  16.  
  17. Raise and safely support the front of the vehicle.
  18.  
  19. Disconnect the T.V. and accelerator cables, then remove the cable bracket.
  20.  
  21. Position the drain pan, then disconnect the heater hose from the bottom of the intake manifold.
  22.  
  23. Unfasten the intake manifold lower mounting bolts/nuts, then carefully lower the vehicle.
  24.  
  25. Remove the upper intake manifold-to-cylinder head nuts/bolts, then remove the intake manifold from the vehicle.
  26.  
  27. Remove and discard the gasket. Use a suitable gasket to carefully and thoroughly clean the mating surfaces on the manifold and cylinder head.
  28.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the intake manifold mounting and bolt tightening sequence - 888-91 2.0L and 2.2L engines

To install:
  1. Position a new intake manifold gasket on the cylinder. Place the intake manifold over the new gasket, then install the retaining bolts/nuts. Tighten the intake manifold-to-cylinder heads bolts, in the sequence shown in the accompanying figure, to 4-22 ft. lbs. (9-30 Nm).
  2.  
  3. Raise the vehicle and support it safely.
  4.  
  5. Connect the heater hoses.
  6.  
  7. Install the cable bracket(s), then connect the T.V. and accelerator cables.
  8.  
  9. Carefully lower the vehicle.
  10.  
  11. Install the TBI unit, then connect the fuel lines and linkage to the TBI unit.
  12.  
  13. Connect all vacuum lines and wires, as tagged during removal.
  14.  
  15. Install the air cleaner assembly.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Fill the engine cooling system with the proper type and amount of coolant.
  20.  

1992-93 VEHICLES

See Figures 2 and 3

  1. Relieve the fuel system pressure, as outlined in Fuel System of this guide.
  2.  
  3. If not already done, disconnect the negative battery cable.
  4.  
  5. Remove the air intake duct.
  6.  
  7. Position a suitable drain pan under the radiator, then drain the cooling system.
  8.  
  9. Tag and disconnect all necessary vacuum lines and wires.
  10.  
  11. Disconnect the throttle linkage.
  12.  
  13. For 894-96 vehicles, remove the serpentine drive belt.
  14.  
  15. Unbolt the power steering pump, then position it aside without disconnecting the fluid lines.
  16.  
  17. For 894-96 vehicles, remove the transaxle fluid level indicator and fill tube.
  18.  
  19. For 894-96 vehicles, detach the electrical connectors from the following components:
    1. MAP sensor
    2.  
    3. EGR solenoid valve
    4.  
    5. Idle Air Control (IAC) valve
    6.  
    7. Throttle Position (TP) sensor
    8.  
    9. Fuel injector wire harness
    10.  

  20.  
  21. Remove the MAP sensor and EGR solenoid valve.
  22.  
  23. Remove the upper intake manifold assembly.
  24.  
  25. Remove the EGR valve injector.
  26.  
  27. Remove the fuel injector retainer bracket, regulator and injectors.
  28.  
  29. Disconnect the accelerator and T.V. cables, then remove the cable bracket.
  30.  



Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the upper intake manifold mounting and bolt tightening sequence - 1993-96 2.2L engines

  1. For 892-93 vehicles, perform the following
    1. Raise the vehicle and support it safely.
    2.  
    3. Remove the 6 intake manifold lower mounting nuts.
    4.  
    5. Carefully lower the vehicle.
    6.  
    7. Unfasten the lower intake manifold upper mounting nuts, then remove the manifold.
    8.  

  2.  
  3. For 894-96 vehicles, perform the following:
    1. Remove the EGR valve pipe.
    2.  
    3. Remove the lower intake manifold-to-cylinder head retaining nuts and studs, then remove the lower intake manifold from the vehicle.
    4.  

  4.  
  5. Remove and discard the gasket. Use a suitable gasket to carefully and thoroughly clean the mating surfaces on the manifold and cylinder head.
  6.  



Click image to see an enlarged view

Fig. Fig. 3: Lower intake manifold mounting and bolt tightening sequence - 1993-96 2.2L engines

To install:
  1. Position a new intake manifold gasket on the cylinder, then place the lower intake manifold over the new gasket. For 894-96 vehicles, install the retaining nuts and studs. Tighten the studs to 89 inch lbs. (10 Nm) and the nuts, in sequence, to 24 ft. lbs. (33 Nm).
  2.  
  3. For 894-96 vehicles, install the EGR valve pipe.
  4.  
  5. Connect the fuel lines.
  6.  
  7. Install the fuel injectors, regulator and injector retainer bracket and tighten the retaining bolts to 22 inch lbs. (3.5 Nm).
  8.  
  9. Install the cable bracket, then connect the accelerator and T.V. cables.
  10.  
  11. For 892-93 vehicles, perform the following:
    1. Raise the vehicle and support it safely.
    2.  
    3. Tighten the lower intake manifold nuts in the proper sequence to 22 ft. lbs. (30 Nm).
    4.  
    5. Carefully lower the vehicle.
    6.  

  12.  
  13. Install the EGR valve injector so that the port is facing directly towards the throttle body.
  14.  
  15. Install the upper intake manifold assembly. Tighten the upper intake manifold nuts in the proper sequence to 22 ft. lbs. (30 Nm).
  16.  
  17. Install the MAP sensor and EGR solenoid valve.
  18.  
  19. For 894-96 vehicles, install the serpentine drive belt.
  20.  
  21. Install the accelerator cable bracket and throttle linkage. Tighten the cable bracket bolts to 7 ft. lbs. (25 Nm).
  22.  
  23. Connect the vacuum lines and wires as tagged during removal.
  24.  
  25. Attach the air intake duct.
  26.  
  27. Position the power steering pump and secure with retaining bolts.
  28.  
  29. For 894-96 vehicles, install the transaxle fluid level indicator and fill tube.
  30.  
  31. Connect the negative battery cable.
  32.  
  33. Fill the engine cooling system with the proper type and amount of coolant.
  34.  

2.3L Engine

See Figures 4, 5 and 6

  1. Disconnect the negative battery cable.
  2.  
  3. Position a suitable container under the radiator, then drain the cooling system.
  4.  
  5. Detach the vacuum hose and electrical connector from the MAP sensor.
  6.  
  7. Unplug the electrical connectors from the following components:
    1. Manifold Absolute Pressure (MAP) sensor.
    2.  
    3. Intake Air Temperature (IAT) sensor.
    4.  
    5. EVAP canister purge solenoid.
    6.  
    7. Fuel injector harness.
    8.  

  8.  
  9. Detach the vacuum hoses from the fuel pressure regulator and EVAP canister purge solenoid.
  10.  
  11. Disconnect the throttle body-to-air cleaner duct.
  12.  
  13. Remove the accelerator control cable bracket.
  14.  



Click image to see an enlarged view

Fig. Fig. 4: Exploded view of the accelerator control cable bracket

  1. Disconnect the power brake vacuum hose, including the retaining bracket to the power steering bracket and position it aside.
  2.  
  3. For 890-92 vehicles, disconnect the coolant lines from the throttle body.
  4.  
  5. Remove the oil/air separator (crankcase ventilation system), as follows:
    1. Leave the hoses attached to the separator.
    2.  
    3. Disconnect the hoses from the oil fill, chain cover intake duct and intake manifold.
    4.  
    5. Remove the oil/air separator as an assembly.
    6.  

  6.  

  1. Remove the oil fill cap and oil level dipstick.
  2.  
  3. Remove the oil fill tube bolt/screw, then pull the oil fill tube upward to unseat from block and remove.
  4.  
  5. Disconnect the injector harness connector.
  6.  
  7. Remove the fill tube from the top, rotating as necessary to gain clearance for the oil/air separator nipple between the intake tubes and fuel rail electrical harness.
  8.  
  9. Remove the intake manifold support bracket bolts and/or nut. Remove the intake manifold attaching nuts and bolts.
  10.  
  11. Remove the intake manifold.
  12.  



Click image to see an enlarged view

Fig. Fig. 5: The intake manifold brace is secured with three bolts

The intake manifold mounting hole closest to chain housing is slotted for additional clearance.



Click image to see an enlarged view

Fig. Fig. 6: Exploded view of the intake manifold and bolt tightening sequence

To install:
  1. Install the intake manifold and gasket. Tightening the intake manifold bolts/nuts in sequence and to 7 ft. lbs. (25 Nm). Tighten intake manifold brace and retainers hand tight. Tighten to specifications in the following sequence:
    1. Nut to stud bolt: 7 ft. lbs. (25 Nm).
    2.  
    3. Bolt to intake manifold: 40 ft. lbs. (55 Nm).
    4.  
    5. Bolt to cylinder block: 40 ft. lbs. (55 Nm).
    6.  

  2.  
  3. Lubricate a new oil fill tube ring seal with engine oil. Install the tube between No.10 and 2 intake tubes. Rotate as necessary to gain clearance for oil/air separator nipple on fill tube.
  4.  
  5. Locate the oil fill tube in its cylinder block opening. Align the fill tube so it is approximately in its installed position. Place the palm of the hand over the oil fill opening and press straight down to seat fill tube and seal into cylinder block.
  6.  
  7. Install oil/air separator assembly, it may be necessary to lubricate the hoses for ease of assembly.
  8.  
  9. Using a new gasket, install the throttle body to the intake manifold.
  10.  
  11. Attach the injector harness connector.
  12.  
  13. Install the oil fill cap and oil level dipstick.
  14.  
  15. Connect the power brake vacuum hose.
  16.  
  17. Install the throttle cable bracket.
  18.  
  19. Connect the throttle body to air cleaner duct.
  20.  
  21. Install the cooling fan shroud, vacuum hose and electrical connector to the MAP sensor.
  22.  
  23. Connect the negative battery cable.
  24.  

2.8L and 3.1L (VIN T) Engines

See Figure 7

  1. Properly relieve the fuel system pressure, as outlined in Fuel System of this guide.
  2.  
  3. If not already done, disconnect the negative battery cable.
  4.  
  5. Position a suitable drain pan under the radiator, then drain the cooling system.
  6.  
  7. Disconnect the T.V. and accelerator cables from the plenum.
  8.  
  9. Remove the throttle body-to-plenum bolts and the throttle body. Remove the EGR valve.
  10.  
  11. Remove the plenum-to-intake manifold bolts and the plenum. Disconnect and plug the fuel lines and return pipes at the fuel rail.
  12.  
  13. Remove the serpentine drive belt.
  14.  
  15. Remove the power steering pump-to-bracket bolts and support the pump out of the way; but DO NOT disconnect the pressure hoses.
  16.  
  17. Remove the alternator-to-bracket bolts and support the alternator out of the way.
  18.  
  19. Loosen the alternator bracket. From the throttle body, disconnect the idle air vacuum hose.
  20.  
  21. Label and disconnect the electrical connectors from the fuel injectors. Remove the fuel rail.
  22.  
  23. Remove the breather tube. Disconnect the runners.
  24.  
  25. Remove both rocker arm cover-to-cylinder head bolts and the covers. Remove the radiator hose from the thermostat housing.
  26.  
  27. Label and unplug the electrical connectors from the coolant temperature sensor and oil pressure sending unit. Remove the coolant sensor.
  28.  
  29. Remove the bypass hose from the filler neck and cylinder head.
  30.  
  31. Unfasten the intake manifold-to-cylinder head bolts, then remove the intake manifold from the vehicle. Remove and discard the gaskets.
  32.  
  33. Loosen the rocker arm nuts, turn them 90° and remove the pushrods; be sure to keep the components in order for installation purposes.
  34.  
  35. Using a suitable gasket scraper and degreaser, carefully and thoroughly clean all gasket mounting surfaces.
  36.  



Click image to see an enlarged view

Fig. Fig. 7: Exploded view of the intake manifold mounting and bolt tightening sequence - 2.8L and 3.1L (VIN T) engines

To install:
  1. Use new gaskets and place a 16 in. (5mm) bead of RTV sealant on the ridges of the manifold.
  2.  
  3. Install the pushrods in their original positions, then tighten the rocker arm nuts to 7 ft. lbs. (25 Nm).
  4.  
  5. Install the intake manifold and tighten (following the torquing sequence) the intake manifold-to-cylinder head bolts to 4 ft. lbs. (9 Nm) and retighten to 24 ft. lbs. (33 Nm).
  6.  
  7. Attach the heater inlet pipe.
  8.  
  9. Install the coolant sensor, then connect the wires to the coolant sensor and oil sending unit.
  10.  
  11. Install the radiator hose at the thermostat outlet.
  12.  
  13. Fill the cooling system.
  14.  
  15. Install the rocker arm cover, then attach the breather tube.
  16.  
  17. Install the fuel rail.
  18.  
  19. Attach the wires at the injectors.
  20.  
  21. Connect the idle air vacuum hose to the throttle body.
  22.  
  23. Install the alternator bracket and the alternator.
  24.  
  25. Install the power steering pump.
  26.  
  27. Install the serpentine belt.
  28.  
  29. Install the fuel inlet and return lines at the fuel rail.
  30.  
  31. Install the plenum.
  32.  
  33. Install the EGR valve.
  34.  
  35. Attach the throttle body to the plenum.
  36.  
  37. Install the accelerator and T.V. cable bracket at the plenum.
  38.  
  39. Connect the negative battery cable, then start the vehicle and check for leaks.
  40.  
  41. Check the cooling system level, and top off as necessary.
  42.  

3.1L (VIN M) Engine

See Figure 8 through 24

  1. Properly relieve the fuel system pressure, as outlined in Fuel System of this information.
  2.  
  3. If not already done, disconnect the negative battery cable.
  4.  
  5. Remove the top half of the air cleaner assembly and the throttle body duct.
  6.  
  7. Place a suitable container under the radiator, then drain the cooling system.
  8.  
  9. Remove the EGR pipe from the exhaust manifold.
  10.  
  11. Remove the serpentine drive belt.
  12.  
  13. Disconnect brake vacuum pipe from the plenum.
  14.  
  15. Remove the power steering lines from the alternator bracket, then remove the alternator.
  16.  
  17. Tag and disconnect the spark plug wires from the plugs, then detach the harness from the plenum.
  18.  
  19. At the same time, remove the electronic ignition coil and module assembly and the EVAP canister purge solenoid.
  20.  
  21. Tag and detach the upper engine wiring harness connectors from the following components:
    1. Throttle Position (TP) sensor.
    2.  
    3. Idle Air Control (IAC) valve.
    4.  
    5. Injector harness.
    6.  
    7. Engine Coolant Temperature (ECT) sensor.
    8.  
    9. Manifold Absolute Pressure (MAP) sensor.
    10.  
    11. Camshaft Position (CMP) sensor.
    12.  

  22.  
  23. Label and disconnect the vacuum lines from the vacuum modulator, fuel pressure regulator and PCV valve.
  24.  
  25. Remove the MAP sensor.
  26.  
  27. Remove the retaining bolts, then remove the upper intake manifold.
  28.  
  29. Disconnect the fuel lines from the fuel rail, then remove them from the bracket.
  30.  
  31. Install tool J 38467-A or equivalent engine support fixture.
  32.  
  33. Remove the right engine mount.
  34.  
  35. Unfasten the power steering pump mounting bolts, then position the pump aside. DO NOT disconnect the fluid lines.
  36.  
  37. Disconnect the coolant inlet pipe from the coolant outlet housing.
  38.  
  39. Detach the coolant bypass at the water pump and cylinder head.
  40.  
  41. Disconnect the radiator hose from the coolant outlet housing, then remove the coolant outlet housing.
  42.  
  43. Remove both rocker arm (valve) covers.
  44.  
  45. Remove the lower intake manifold mounting bolts, making sure to keep the washers on the center bolts in their original positions. Remove the lower intake manifold from the vehicle.
  46.  
  47. Loosen the rocker arms, then remove the pushrods. Keep the pushrods organized, so they can be installed in their original positions.
  48.  
  49. Remove and discard the intake manifold gasket. Thoroughly clean the gasket mating surfaces with a suitable degreaser.
  50.  



Click image to see an enlarged view

Fig. Fig. 8: Unfasten the retaining bolts, then remove the MAP sensor



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Fig. Fig. 9: Remove the upper intake manifold (plenum) retaining bolts ...



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Fig. Fig. 10: ... then remove the upper manifold from the engine



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Fig. Fig. 11: Unfasten the top engine mount-to-mount bracket retaining bolts ...



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Fig. Fig. 12: ... then remove the side engine mount-to-mount bracket retaining bolts ...



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Fig. Fig. 13: ... and remove the engine mount bracket from the vehicle



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Fig. Fig. 14: Remove the engine mount retaining bolts ...



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Fig. Fig. 15: ... then remove the engine mount from the vehicle



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Fig. Fig. 16: Remove the power steering pump and pulley mounting bolts ...



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Fig. Fig. 17: ... then remove the power steering pump and position aside with the fluid lines attached



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Fig. Fig. 19: Remove the retaining bolts, then remove the valve covers from the vehicle



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Fig. Fig. 20: Remove the lower intake manifold mounting bolts ...



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Fig. Fig. 21: ... then remove the lower intake manifold from the vehicle



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Fig. Fig. 22: For access to the pushrods (A), loosen the rocker arm (B) retaining bolt s (C) ...



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Fig. Fig. 23: ... then remove the pushrods and place them in a suitable holder to keep them in order



Click image to see an enlarged view

Fig. Fig. 24: Remove the intake manifold gasket and replace with a new one during installation

To install:
  1. Place a 2-3mm bead of RTV sealer on each ridge where the front and rear of the intake manifold contact the block, then position a new intake manifold gasket.
  2.  

Intake pushrods are 53/4inches long and marked red, and exhaust pushrods are 6 inches long and marked blue.

  1. Coat the ends of the pushrods with prelube10052356 or equivalent. Install the pushrods in their original locations, making sure they are properly seated in the lifters.
  2.  
  3. Install the rocker arms nuts and tighten to 7 ft. lbs. (24 Nm).
  4.  
  5. Coat the threads of the lower intake manifold bolts with sealant 245739 or equivalent. Position the lower intake manifold and secure with the retaining bolts. Tighten the bolts104 inch lbs. (2 Nm).
  6.  
  7. Install the front rocker arm (valve) cover.
  8.  
  9. Install the coolant outlet housing. Connect the radiator hose to the thermostat housing.
  10.  
  11. Attach the coolant inlet pipe to the thermostat housing. Attach the coolant bypass pipe to the water pump and cylinder head.
  12.  
  13. Position the power steering pump, then secure with the retaining bolts.
  14.  
  15. Install the serpentine drive belt, loosely, due to the trap design.
  16.  
  17. Install the right engine mount, then remove the engine support fixture.
  18.  
  19. Attach the fuel lines to the fuel rail and bracket.
  20.  
  21. Install the upper intake manifold and tighten the retaining bolts to 7 ft. lbs. (25 Nm).
  22.  
  23. Install the MAP sensor.
  24.  
  25. Connect the vacuum lines to the PCV valve, fuel pressure regulator and vacuum modulator, as tagged during removal.
  26.  
  27. Attach the electrical connectors to the following components, as tagged during removal:
    1. Camshaft Position (CMP) sensor.
    2.  
    3. Manifold Absolute Pressure (MAP) sensor.
    4.  
    5. Engine Coolant Temperature (ECT) sensor.
    6.  
    7. Injector harness.
    8.  
    9. Idle Air Control (IAC) valve.
    10.  
    11. Throttle Position (TP) sensor.
    12.  

  28.  
  29. Install the EVAP canister purge solenoid and the ignition coil and module assembly.
  30.  
  31. Install the alternator, then attach the power steering line to the alternator bracket.
  32.  
  33. Install the serpentine drive belt.
  34.  
  35. Connect the spark plug wires to the plugs, as tagged during removal.
  36.  
  37. Attach the EGR pipe to the exhaust manifold.
  38.  
  39. Fasten the throttle control and cruise control cables to the throttle body.
  40.  
  41. Install the air intake duct and the top half of the air cleaner assembly.
  42.  
  43. Connect the brake vacuum pipe. Attach the cables to the throttle body.
  44.  
  45. Fill the cooling system to the correct level with the proper type and amount of coolant.
  46.  
  47. Connect the negative battery cable, then start the engine and check for leaks.
  48.  

 
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