OEM 2000 Chevrolet Malibu Intake Manifold

2000 Chevrolet Malibu Intake Manifold Parts Questions & Experts Answers

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

  A: Begin the lower Intake Manifold replacement by disconnecting the battery ground cable. Begin by removing the upper Intake Manifold followed by taking off the left and right valve Rocker Arm covers. The Fuel Injector and manifold air pressure (MAP) wiring harness follows the removal of the engine coolant temperature (ECT) wiring harness. Unfasten the fuel pipe clip bolt along with its clip before disconnecting the fuel feed and return pipes from the Fuel Injector rail for rail removal. Move the Power Steering Pump to an alternate location before removing it from the front engine cover and perform the next step by separating the heater inlet pipe and heater hose from the lower Intake Manifold and disconnect the radiator inlet hose from the engine. Begin by disconnecting the Thermostat bypass hose before removing the lower Intake Manifold bolts and the manifold itself together with rocker arms and push rods. Use degreaser to clean all surfaces including the engine block, cylinder heads, and lower Intake Manifold gaskets and seals before removing the loose rtv sealer from these components. Replacement of the lower Intake Manifold requires removal of ect sensor and lower bolts next to the water outlet followed by removal of the outlet and subsequently the Thermostat. The installation process starts with the Thermostat followed by water outlet installation before tightening bolts to 25 nm (18 ft. Lbs.). The procedure demands installation of the ect sensor after which you should tighten it to 23 nm (17 ft. Lbs.). Use an 8 - 12 mm bead (0.08 - 0.11 inch) of rtv sealer gm p/n 12345739 or equivalent to coat each ridge where the lower Intake Manifold makes contact with the engine block before installing the gaskets. After reinstalling the valve rocker arms and pushrods, install the lower Intake Manifold. Sealant gm p/n 12345382 must be applied to lower Intake Manifold bolts before hand tightening vertical and diagonal bolts followed by properly torquing all lower intake bolts to 13 nm (115 inch lbs.). Seal the lower Intake Manifold by connecting the Thermostat bypass hose and radiator inlet hose and heater inlet pipe with heater hose. Begin by reinstalling the Power Steering Pump followed by the Fuel Injector rail while connecting both fuel return and feed pipes to it. Fasten the fuel pipe clip by installing its bolt and torque it to 8 nm (71 inch lbs.). The installation process continues with the upper Intake Manifold and later includes the ect wiring harness connection followed by the map wiring harness and finally the Fuel Injector connection. Refasten the battery's ground (negative) cable.