OEM 2000 Chevrolet Malibu Intake Manifold

2000 Chevrolet Malibu Intake Manifold Parts and Q&A

• Q: How to replace the upper intake manifold on 2000 Chevrolet Malibu?

  A: The upper Intake Manifold replacement process begins by disconnecting the battery's negative cable and removing the air cleaner's upper portion. Remove the brake vacuum pipe at the plenum followed by draining and recovering the cooling system. Start by disconnecting the Fuel Pressure Regulator vacuum hose from the Fuel Pressure Regulator and PCV Valve before taking out the Spark Plug Wires. Take out the electronic Ignition Coil and module assembly and the evap canister purge solenoid then disconnect the throttle position (TP) sensor, iac sensor, injector harness, engine coolant temperature (ECT) sensor, camshaft position (CMP) sensor and vacuum modulator. The MAP Sensor vacuum line should be disconnected while you remove both bolts that secure the sensor assembly and disconnect its electrical connector. The repair process ends by removing upper Intake Manifold bolts and replacing the upper Intake Manifold and gaskets before cleaning both surfaces. Install upper Intake Manifold gaskets onto the manifold then treat each bolt thread with gm p/n thread lock substance 12345382 before firmly tightening all bolts to 25 nm (18 ft. Lbs). Join all components starting with the MAP Sensor bolts then add the MAP Sensor vacuum line followed by connecting the MAP Sensor electrical connector and joining the vacuum modulator to the Fuel Pressure Regulator as well as the crankcase ventilation valve and the vacuum hose. Reestablish connections for the throttle position (TP) sensor and iac along with injector harnesses and engine coolant temperature (ECT) sensor and camshaft position (CMP) sensor harnesses. Mount the evap canister purge solenoid followed by the electronic Ignition Coil and module assembly and the secondary ignition wires to their spark plug and harness at the plenum. Connect the throttle body cable alongside the cruise control cable to your throttle body before reinstalling both the air cleaner top half and brake vacuum pipe. After refilling the cooling system you must reconnect the Battery Cable and do a leak and fluid inspection.