OEM 2002 Chevrolet Malibu Intake Manifold

2002 Chevrolet Malibu Intake Manifold Parts Questions & Experts Answers

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

  A: Prerequisite steps to replace the lower Intake Manifold require complete removal of the upper Intake Manifold followed by detachment of right (rear) and left (front) valve Rocker Arm covers. You should disconnect the engine coolant temperature (ECT) sensor electrical connector before removing the fuel injector rail with lines for placement aside. The initial step involves moving the Power Steering Pump to a different position on the front engine cover followed by disconnecting the heater inlet pipe with heater hose from the lower Intake Manifold. Begin by removing the lower Intake Manifold bolts and the lower Intake Manifold followed by the rocker arms and push rods before extracting the lower Intake Manifold gaskets and seals. The ect sensor, water outlet bolts, water outlet and Thermostat must be removed from the replacement lower Intake Manifold process. Installation requires the therapist to be reinstalled with the water outlet secured by bolts to 25 nm (18 ft. Lbs) while the ect sensor receives 23 nm (17 ft. Lbs) torque. Apply a 0.08 to 0.11 inch (8 to 12 mm) rtv sealer bead matching gm p/n 12345739 or similar product to the ridge regions connecting the front and rear lower Intake Manifold sections and engine block structures before installing gaskets and pushrods along with rocker arms. For the lower Intake Manifold installation combine gm p/n 12345382 sealant with the Intake Manifold bolts threads. Start by torquing the vertical lower Intake Manifold bolts until they become snug then torque the diagonal bolts until they achieve the same state. Use new lower Intake Manifold bolts and follow the installation order by applying 7 nm (62 in. Lbs) torque first before advancing to 13 nm (115 in. Lbs) for bolts (1,2,3,4) while final torque at 25 nm (18 ft. Lbs) should be applied to bolts (5,6,7,8). Reinstall the Power Steering Pump to its position on the front engine cover while completing the installation of lower Intake Manifold heater bolts and heater pipe connections and ect sensor wiring and finally securing upper Intake Manifold and valve covers.