Chevrolet 55494090 Manifold Assembly, Intake (W/ Throttle Body)

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Terminate the connection of the negative terminal from the battery and relieve the fuel system of the pressure. In the 2.0L engine, the following measures are taken: drain the cooling system. Removal of the oil filler cap and the fastener of the engine cover, which should then be lifted off from the ball studs in case of the 1.5L engine. Wrinkle out the intake manifold sound insulator and loose the charge air cooler outlet pipe of the throttle body. Disconnect the fuel feed line and its bracket from the intake manifold, take off the canister purge line from the quick-connector of the throttle body, and unscrew the bracket connected to the throttle body and the electrical connectors of the intake air pressure sensor. Remove the canister purge solenoid electrical connector, and unclip the solenoid from the intake manifold bracket tab, then route and secure the hose for it. Unfasten all the remaining electrical connections which might hinder manifold removal; then open all the clips of the wiring harnesses and pull all the wiring harnesses off the manifold. Remove the intake manifold fasten bolts, then, slowly remove the intake manifold from the cylinder head. Slide a new intake manifold gasket over the grooved recess in the intake manifold and align the gasket accurately with the provision and clean the mating surfaces of the intake manifold and cylinder head. Position the manifold to the cylinder head and use your fingers tight the bolts then increase the intensity until you reach the standard torque. The rest is again as removal, reconnecting the battery, and using the engine for vacuum and fuel leak test. In 2.0L and 2.5L engines, remove the charge air cooler outlet pipe from the throttle body, fuel feed pipe quick-connect fitting for 2.0L and 2.5L engines and coolant air bleed pipe hose for the 2.0L engines, the hose to be plugged and the pipe capped. Before removing the PCV fresh air tube you must of course remove the air intake duct to the throttle body, fuel rail with injectors attached to it, and the power brake booster vacuum line that is connected to the tube. As you will see, the PCV valve and tube assembly are not interchangeable, so if you are removing the intake manifold, do not remove them from the valve camshaft. Pull off the EVAP canister purge solenoid valve, throttle body and high pressure fuel pump, unclip the intake manifold cover and take it off. Any electrical connector that would hinder the removal of the manifold has to be disconnected, the wiring harness clips to be opened, and any wiring harness connected to the manifold to be disconnected. Unfasten the intake manifold mounting bolts, these are the 14mm in the case of the 2.0L engines while these bolts are recessed in the intake manifold and should not be lost. Detach the intake manifold from the cylinder head to get access for a fuel pressure sensor, detach the electrical connector from a fuel pressure sensor, and then disconnect the intake manifold. Introduce a fresh intake manifold gasket in the grooved channel of the intake manifold; align it correctly by making use of indexing lugs and lifter, and make certain that the mating surfaces between the intake manifold and cylinder head are free of deposits or debris. Fit the manifold onto its position near to the cylinder head connect the fuel pressure sensor again turn the manifold toward cylinder head and flexible tighten the bolts. Torque the bolts in a sequence up to prescribed torque , then reverse the installation procedure, connect the battery and start the engine and check for vacuum and fuel leaks.