For 1990-2009 cars

### Removal Procedure

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
2. Remove the air cleaner duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls - 2.4 L.
3. Disconnect the following electrical connectors:

• | Manifold absolute pressure (MAP) sensor

• | Intake air temperature (IAT) sensor

• | Evaporative emissions (EVAP) canister purge solenoid

• | Fuel injector harness

4. Disconnect the vacuum hoses from the fuel regulator and the EVAP canister purge solenoid to the canister.
5. Remove the accelerator control cable bracket.
6. Remove the stud-end generator mount bolt.
7. Remove brake booster vacuum line.
8. Remove wiring harness from retainers on bottom of intake manifold.
9. Remove the intake manifold nuts and bolts.
10. Remove the intake manifold and the gasket.

### Installation Procedure

Important: The engine and the manifold should be at ambient temperature when assembled. Do NOT attempt to install a cold manifold on a hot engine.

1. Install the intake manifold and the gasket. If damaged, install a new gasket with the stamped numbers facing towards the manifold surface.

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.

2. Install the intake manifold nuts and bolts in the sequence shown.

Tighten
Tighten the intake manifold bolts/nuts to 24 N·m (18 lb ft).

3. Install wiring harness to retainers on bottom of intake manifold.
4. Install brake booster vacuum line.
5. Install the stud-end generator mount bolt.
6. Install the accelerator control cable bracket.
7. Connect the vacuum hoses to the fuel regulator and to the EVAP canister purge solenoid.

Important: If you have removed the IAT sensor, apply sealant GM P/N 1052080 or equivalent to the threads before installation.

8. Connect the following electrical connections:

• | MAP sensor

• | IAT sensor

• | EVAP canister purge solenoid

• | Fuel injector harness

9. Install the air cleaner duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls - 2.4 L.
10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.