OEM 2002 Chevrolet Malibu Intake Manifold

2002 Chevrolet Malibu Intake Manifold Parts and Q&A

• Q: How to replace the upper intake manifold on 2002 Chevrolet Malibu?

  A: To remove the upper Intake Manifold, start by removing the top half of the air cleaner assembly, draining the cooling system and removing the brake vacuum pipe at the plenum. Pull off the Fuel Pressure Regulator vacuum hose away from the Fuel Pressure Regulator and PCV Valve, remove the electronic Ignition Coil and module assembly, throttle cable bracket with cables, evap canister purge solenoid, throttle position (TP) sensor, idle air control (IAC) sensor, fuel injector harness, and the manifold absolute pressure (MAP) sensor. Then take off the egr pipe, the inlet and outlet hoses attached to the Throttle Body, the upper Intake Manifold bolts. Remove the upper Intake Manifold and gaskets and clean the gasket surfaces. For installation, set the upper bottle of gaskets to manifold and apply thread lock gm p/n 12345382 to threads of bolts, for the upper Intake Manifold bolts tighten to 25 nm (18 ft. Lbs.). Replace the MAP Sensor , egr pipe , and inlet and outlet hose from Throttle Body . Reconnect the vacuum hose to the Fuel Pressure Regulator and the crankcase ventilation valve, then tp sensor, iac, and fuel injector harness. Mount the evap canister purge solenoid, electronic Ignition Coil and module assembly, throttle cable bracket and cables from the Throttle Body, as well as the top half of the air cleaner assembly. Finally, reinstall the brake vacuum pipe, top up the cooling system, and look for adequate fluid levels and leaks.