GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2001 🢒 Cavalier 🢒 Engine 🢒 Engine Electrical 🢒 Intake Manifold Replacement

Removal Procedure
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief in Engine Controls.

    2. Object Number: 193392 Size: SH
  2. Remove the air cleaner inlet duct (1).

    3. Object Number: 193394 Size: SH
  3. Remove the resonator.

    4. Object Number: 193395 Size: SH
  4. Remove the resonator bracket/fuel rail cover.
  5. Disconnect the vacuum hoses at the throttle body.

    6. Object Number: 183480 Size: SH
  6. Remove the throttle body. Refer to Throttle Body Assembly Replacement in Engine Controls.

    7. Object Number: 193512 Size: SH
  7. Disconnect the MAP sensor.

    8. Object Number: 193410 Size: SH
  8. Remove fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls.
  9. Raise vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  10. Disconnect the following components:
    11. • Evap purge solenoid
    • Camshaft sensor
    • Crankshaft sensor
    • VSS
    • Knock sensor
    • Back-up lamp switch
    • Oxygen sensor
    • Oil pressure switch
  11. Lower vehicle.
  12. Unroute wiring harness.
  13. Remove the intake manifold attaching nuts and the bolts.

    14. Object Number: 182943 Size: SH
  14. Remove the intake manifold from the engine.
  15. Clean the mating surfaces on the intake manifold and the cylinder head.
  16. Inspect the manifold for cracks, broken flanges, and gasket surface damage.

Installation Procedure
  1. Install the intake manifold assembly.

    2. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.


    Object Number: 182943 Size: SH
  2. Install the intake manifold to cylinder head bolts and the nuts.

    3. Tighten

        • Tighten nuts and bolts to 24 N·m (17 lb ft).
        • Tighten studs to 12 N·m (107 lb in).
  3. Route wiring harness.
  4. Raise vehicle.
  5. Connect the following components:
    6. • Evap purge solenoid
    • Camshaft sensor
    • Crankshaft sensor
    • VSS
    • Knock sensor
    • Back-up lamp switch
    • Oxygen sensor
    • Oil pressure switch

    Object Number: 193410 Size: SH
  6. Install the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls.

    7. Object Number: 193512 Size: SH
  7. Connect the MAP sensor.

    8. Object Number: 183480 Size: SH
  8. Install the throttle body. Refer to Throttle Body Assembly Replacement in Engine Controls.

    9. Object Number: 193395 Size: SH
  9. Install the resonator bracket/fuel rail cover.

    10. Object Number: 193394 Size: SH
  10. Install the resonator.

    11. Object Number: 193392 Size: SH
  11. Install the air cleaner inlet duct (1).