OEM 2005 Chevrolet Malibu Intake Manifold

2005 Chevrolet Malibu Intake Manifold Parts Questions & Experts Answers

• Q: How to replace the upper intake manifold on 2005 Chevrolet Malibu?

  A: The replacement of the upper Intake Manifold requires disconnecting the negative Battery Cable then removing vacuum hoses from four system components: the evaporative emissions canister purge valve along with manifold vacuum source and Brake Booster and finally the heater and a/c source. After disconnecting the negative Battery Cable it's important to detach power wires from an exhaust gas recirculation (EGR) valve and a mass air flow (MAF) sensor and intake air temperature (IAT) sensor and electronic throttle control and evap canister purge valve. First drain the cooling system while removing the air cleaner intake duct. The next step requires removal of left-side Spark Plug Wires from spark plugs and detachment of wiring harnesses for the camshaft position (CMP) sensor and left side Spark Plug Wires and engine wiring harness from their retaining points. Start by removing the Ignition Coil bracket containing the coils and also take off the evap canister purge solenoid valve and manifold absolute pressure (MAP) sensor with its bracket and EGR Valve. Start by removing upper Intake Manifold bolts with their stud before extracting the upper manifold and its gaskets. The Throttle Body needs to be removed during upper Intake Manifold replacement while professionals should clean up both upper intake gasket mating surfaces. Put the Throttle Body back in position first followed by upper Intake Manifold gaskets and the upper Intake Manifold installation. Tighten right upper Intake Manifold bolts and the stud to 25 nm (18 ft. Lbs.). Place the EGR Valve into position before installing both the MAP Sensor bracket and sensor alongside the evap canister purge solenoid valve. Connect the Ignition Coil bracket along with coils and wiring harnesses to their proper retainers. The Spark Plug Wires and air cleaner intake duct need installation to the left side spark plugs. Route electrical wires toward the evap canister purge valve along with the electronic throttle control and iat sensor and maf sensor and EGR Valve. As the final step connect vacuum lines to the heater and a/c source then install the lines to the Brake Booster while adding fuel to the evap canister purge valve before reinstalling the negative Battery Cable and completing the cooling system flow.