Intake Manifold Removal on Chevrolet Malibu?

The intake manifold removal for 2.2L, 3.5L and 3.9L engine models.

The complete details to replace upper/lower left/right Intake manifold for for Chevrolet Malibu.

The details are as follows:----

Removal & Installation

2.2L Engines

1. Before servicing the vehicle, refer to the Precautions Section.
2. Drain the cooling system.
3. Relieve the fuel system pressure.
4. Remove or disconnect the following:
   
   
   Negative battery cable

   Air intake assembly

   Throttle body

   PCV hose

   Purge solenoid tube

   Brake booster vacuum hose

   Oil level indicator tube mounting bolt

   Fuel rail

   Knock Sensor (KS) electrical connector and wiring harness

   Intake manifold mounting bolts

   Intake manifold

To install:

1. Install or connect the following:
   
   
   Intake manifold and gasket. Tighten bolts to 89 inch lbs. (10 Nm).

   KS sensor electrical connector

   Fuel rail

   Oil level indicator tube mounting bolt. Tighten to 89 inch lbs. (10 Nm).

   Brake booster vacuum hose

   Purge solenoid rube

   PCV hose

   Throttle body

   Air intake assembly

   Negative battery cable
2. Refill the cooling system.
3. Start the engine and check for leaks.

3.5L Engine
Lower Manifold

1. Before servicing the vehicle, refer to the Precautions Section.
2. Drain the cooling system.
3. Relieve the fuel system pressure.
4. Remove or disconnect the following:
   
   
   Negative battery cable

   Upper intake manifold

   Valve covers

   Engine coolant temperature (ECT) wiring harness

   Fuel injector wiring harness

   Manifold air pressure (MAP) wiring harness

   Fuel rail

   Heater inlet pipe with heater hose from the lower manifold and place aside

   Upper radiator hose

   Thermostat housing inlet pipe

   Thermostat

   Lower intake manifold mounting bolts

   Lower intake manifold

   Rocker arms and pushrods

   Lower intake manifold gaskets

To install:

1. Install the lower intake manifold gaskets.
2. Install the rocker arms and pushrods.
3. With the gaskets in place, apply a small drop of RTV sealant to the four corners of the manifold-to-engine block joints.
4. Install the lower intake manifold. Tighten bolts to as follows:
   1. Step 1: Apply GM P/N 12345382 sealer or equivalent to the bolt threads.
   2. Step 2: Tighten all bolts 115 inch lbs. (13 Nm).
   3. Step 3: Tighten bolts 1-4 in sequence to 15 ft. lbs. (20 Nm).
   4. Step 4: Tighten bolts 5-8 in sequence to 18 ft. lbs. (25 Nm).
5. Install or connect the following:
   
   
   Heater inlet pipe

   Thermostat

   Thermostat housing inlet pipe

   Upper radiator hose

   Heater inlet pipe and heater hose

   Fuel rail

   MAP wiring harness

   Fuel injector and MAP wiring harness

   ECT wiring harness

   Valve covers

   Upper intake manifold

   Negative battery cable
6. Refill the cooling system to the correct level.
7. Start the engine and check for leaks.

Upper Manifold

1. Before servicing the vehicle, refer to the Precautions Section.
2. Drain the cooling system.
3. Remove or disconnect the following:
   
   
   Negative battery cable

   EVAP canister purge valve hose

   Manifold vacuum source hose

   Brake booster hose

   Heater and A/C source hose

   Exhaust gas recirculation (EGR) valve electrical connector

   Mass air flow (MAP) sensor electrical connector

   Intake air temperature (IAT) sensor electrical connector

   Throttle control electrical connector

   EVAP canister purge valve electrical connector

   Air intake assembly

   Left side spark plug wires

   Engine wiring harnesses from their retainers

   Ignition coil bracket with the coils

   EVAP canister purge solenoid valve

   MAP sensor

   EGR valve

   Upper intake manifold mounting bolts

   Upper intake manifold

To install:

1. Install or connect the following:
   
   
   Intake manifold with gaskets. Tighten bolts to 18 ft. lbs. (25 Nm)

   EGR valve

   MAP sensor

   EVAP canister purge solenoid valve

   Ignition coil bracket with the coils

   Engine wiring harnesses into the retainers

   Left side spark plug wires

   Air intake assembly

   EVAP canister purge valve electrical connector

   Throttle control electrical connector

   IAT sensor electrical connector

   MAP sensor electrical connector

   EGR valve electrical connector

   Heater and A/C source hose

   Brake booster hose

   Manifold vacuum hose

   EVAP canister purge valve hose

   Negative battery cable
2. Refill the cooling system to the correct level.
3. Start the engine and check for leaks.

3.9L Engine
Lower Manifold

WARNING

This engine uses a sequential multiport fuel injection system. Injector wiring harness connectors must be connected to their appropriate fuel injector or exhaust emissions and engine performance may be seriously affected.

1. Before servicing the vehicle, refer to the Precautions Section.
2. Disconnect the negative battery cable.
3. Remove the coolant crossover pipe.
4. Remove the upper intake manifold. Refer to upper intake manifold replacement.
5. Remove the left valve rocker arm cover.
6. Remove the right valve rocker arm cover.
7. Disconnect the Engine Coolant Temperature (ECT) electrical connector.
8. Disconnect the fuel feed line from the fuel rail.
9. Disconnect the fuel injector inline connector.
10. Remove the fuel injector harness connector bracket bolt from the intake manifold.
11. Disconnect the Camshaft Position (CMP) sensor electrical connector.
12. Remove the fuel injector rail bolts.
13. Remove the fuel rail. 
    
    
    
    Fig. 3.9L Engine fuel rail (1) removal
14. Remove the lower intake manifold bolts.
15. Remove the lower intake manifold. 
    
    
    
    Fig. 3.9L Lower intake removal
16. Loosen the valve rocker arm bolts.
    
    NOTE

    Place the valve train components in a rack in order to ensure that the components are installed in the same location from which they where removed.
17. Remove the valve rocker arms.
18. Remove the push rods.
19. Take note of the following:
    
    
    The intake push rods measure 5.81 inch. (147.51 mm).

    The exhaust push rods measure 6.1 inch. (154.87 mm).
20. Remove the lower intake manifold gaskets and seals. 
    
    
    
    Fig. 3.9L Engine lower intake manifold gaskets and seals
21. Clean the lower intake manifold gasket and seal surfaces on the cylinder heads and the engine block.
22. Clean the gasket and seal surfaces on the lower intake manifold with degreaser.
23. Remove all the loose room temperature vulcanizing sealer (RTV).

To install:

WARNING

RTV sealer is NOT to be placed under the lower intake manifold gaskets.

1. Install the lower intake manifold gaskets and seals.
2. Coat the ends of the push rods using prelube.
3. Install the push rods in their original location.
4. Take note of the following:
   
   
   The intake push rods measure 5.81 inch. (147.51 mm).

   The exhaust push rods measure 6.1 inch. (154.87 mm).
5. Coat the rocker arm friction surfaces using prelube.
   
   NOTE

   Shims (P/N 88894006) may be required under the valve rocker arm pedestals if reconditioning has been performed on the cylinder head or its components.
6. Install the valve rocker arms in their original positions.
7. Install the valve rocker arm bolts and tighten to 25 ft. lbs. (34 Nm).
8. With the new gaskets and seals in place, apply a small drop, 0.031-0.39 inch. (8-10 mm) of RTV sealer to the 4 corners of the intake manifold to engine block joints.
9. Install the lower intake manifold.
   
   NOTE

   Maximum gasket performance is achieved when using new fasteners, which contain a thread-locking patch. If the fasteners are not replaced, a thread locking chemical must be applied to the fastener threads. Failure to replace the fasteners or apply a thread-locking chemical may reduce gasket sealing capability.
10. Apply sealer to the lower intake manifold bolt threads.
11. Install the lower intake manifold bolts.
12. Tighten the lower intake manifold bolts in the sequence shown.
    
    NOTE

    Failure to tighten vertical bolts before the diagonal bolts may cause an oil leak.
    
    
    
    
    

    

    Fig. 3.9L Engine lower intake manifold tightening sequence
13. Tighten the lower intake manifold bolts as follows:
    
    
    Tighten the bolts (1, 2, 3, and 4) in sequence to 12 ft. lbs. (16 Nm).

    Tighten the bolts (5, 6, 7, and 8) in sequence to 18 ft. lbs. (25 Nm).
14. Inspect the fuel rail, fuel injectors and fuel injector O-rings for damage and replace as necessary.
15. Lubricate the fuel injector O-rings using lubricant.
16. Install the injector nozzles into the lower intake manifold injector bores.
17. Press on the injector rail using the palms of both hands until the injector is fully seated.
18. Install the fuel injector rail bolts and tighten to 89 inch. lbs. (10 Nm).
19. Connect the CMP sensor electrical connector.
20. Position the fuel injector harness connector bracket to the intake manifold.
21. Install the fuel injector harness connector bracket bolt and tighten to 71 inch. lbs. (8 Nm).
22. Connect the fuel injector inline connector.
23. Connect the fuel feed line to the fuel rail.
24. Connect the ECT electrical connector.
25. Install the right valve rocker arm cover.
26. Install the left valve rocker arm cover.
27. Install the upper intake manifold. Refer to upper intake manifold replacement.
28. Install the coolant crossover pipe.
29. Fill and bleed the cooling system.
30. Install the intake manifold cover.
31. Connect the negative battery cable.

Upper Manifold

1. Before servicing the vehicle, refer to the Precautions Section.
2. Remove the intake manifold cover.
3. Relieve the fuel system pressure.
4. Disconnect the fuel feed pipe quick connect fitting from the fuel rail.
5. Disconnect the Evaporative Emission (EVAP) pipe from the purge solenoid.
6. Open the retaining clip and remove the fuel and EVAP pipes from the clip.
7. Drain the cooling system.
8. Remove the Positive Crankcase Ventilation (PCV) fresh air tube.
9. Remove the PCV foul air tube.
10. Reposition the brake booster vacuum hose clamp at the intake manifold.
11. Remove the vacuum hose from the intake manifold.
12. Remove the radiator surge tank inlet hose from the inlet pipe.
13. Remove the radiator surge tank inlet pipe bolts.
14. Remove the radiator surge tank inlet pipe.
15. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.
16. Disconnect the evaporative emission EVAP canister purge solenoid electrical connector.
17. Disconnect the Electronic Throttle Control (ETC) electrical connector.
18. Disconnect the inlet manifold valve electrical connector.
19. Remove the air cleaner outlet duct.
20. Disconnect the left side spark plug wires from the spark plugs.
21. Disconnect the left side spark plug wires from the ignition coil.
22. Disengage the spark plug wire retainer clips from the intake manifold bracket and the heater inlet and outlet pipe.
23. Remove the left side spark plug wires.
24. Remove the heater inlet and outlet pipe nuts from the throttle body studs.
25. Remove the inlet and outlet pipe from the studs.
26. Remove the 2 ignition coil bolts.
27. Remove the alternator upper bolt.
28. Remove the alternator ball stud.
29. Remove the alternator rear brace.
30. Remove the upper intake manifold bolts and stud.
31. Separate and remove the upper intake manifold from the lower intake manifold.
32. Remove the upper to lower intake manifold gaskets.
    
    
    

    

    Fig. 3.9L Engine upper intake manifold bolts (1, 2), stud (3) and (4) lower intake manifold

To install:

1. Install the new upper to lower intake manifold gaskets.
2. Set the upper intake manifold onto the lower intake manifold.
3. Apply threadlock to the upper intake manifold bolts and stud threads.
4. Install the upper intake manifold bolts and stud. Tighten to 18 ft. lbs. (25 Nm).
5. Install the alternator rear brace.
6. Install the alternator ball stud and tighten to 15 ft. lbs. (20 Nm).
7. Install the alternator upper bolt and tighten to 37 ft. lbs. (50 Nm).
8. Install the 2 ignition coil bolts. Tighten to 18 ft. lbs. (25 Nm).
9. Install the inlet and outlet pipe to the studs.
10. Install the heater inlet and outlet pipe nuts to the throttle body studs. Tighten the nuts to 89 inch. lbs. (10 Nm).
11. Install the left side spark plug wires.
12. Connect the left side spark plug wires to the spark plugs.
13. Connect the left side spark plug wires to the ignition coil.
14. Engage the spark plug wire retainer clips to the intake manifold bracket and the heater inlet/outlet pipe.
15. Install the air cleaner outlet duct.
16. Connect the inlet manifold valve electrical connector. 
17. Connect the EVAP canister purge solenoid electrical connector
18. Connect the ETC electrical connector
19. Connect the MAP sensor electrical connector.
20. Install the radiator surge tank inlet pipe.
21. Install the radiator surge tank inlet pipe bolts. Tighten the bolts to 89 inch. lbs. (10 Nm).
22. Install the radiator surge tank inlet hose to the inlet pipe.
23. Position the radiator surge tank inlet hose clamp.
24. Install the brake booster vacuum hose to the intake manifold.
25. Position the vacuum hose clamp at the intake manifold.
26. Install the PCV foul air tube.
27. Install the PCV fresh air tube.
28. Install the fuel and EVAP pipes to the retainer clip and close the clip.
29. Connect the fuel feed pipe quick connect fitting to the fuel rail.
30. Connect the EVAP emission pipe to the purge solenoid.
31. Fill and bleed the cooling system.
32. Install the intake manifold cover.
33. Connect the negative battery cable.

These details will help.

Thanks.           

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Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html