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AMEDEE
AMEDEE, CHEVY TECHNICIAN
Category: Chevy
Satisfied Customers: 25830
Experience:  ASE certified tech ADVANCED LEVEL SPECIALIST. Wisconsin certified emissions state inspector
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1997 Cavalier Z24: Chevrolet..the removal of the intake manifold

Resolved Question:

What is the 1997 Cavalier Z24 Chevrolet 2.4 dual overhead cam--what is the removal of the intake manifold?

Penelope Stalter
Submitted: 8 years ago.
Category: Chevy
Expert:  AMEDEE replied 8 years ago.

Hello!

 

Here is the replacement procedure. If you would like pictures... just let me know!

 

REMOVAL PROCEDURE


Disconnect the negative battery cable.
Disconnect the following electrical connectors:
Manifold absolute pressure sensor.
Intake Air Temperature (IAT) sensor.
EVAP Canister Purge solenoid.
Fuel injector harness.
Disconnect the vacuum hoses from the fuel regulator and the EVAP Canister Purge solenoid to the canister.
Remove the air cleaner duct.
Remove the accelerator control cable bracket.



 


Remove the stud ended generator mount bolt.



 


Remove the EGR pipe from the EGR adapter.
Raise and support the vehicle.



 


Remove the intake manifold support brace.
Lower the vehicle.



 


Remove the intake manifold retaining nuts and bolts.
Remove the intake manifold and the gasket.
INSTALLATION PROCEDURE

 

NOTE: The engine and the manifold should be at ambient temperature when assembled. Do not attempt to install a cold manifold on a hot engine.

Install the intake manifold and the gasket. If the gasket is damaged, install a new one with the stamped numbers facing towards the manifold surface.



 


Install the intake manifold fasteners. Tighten the fasteners to 24 Nm (18 ft. lbs.) .
Raise and suitably support the vehicle.



 


Install the intake manifold brace. Finger start all bolts.
Tighten bolt (A) to 24 Nm (18 ft. lbs.) .
Tighten bolt (B) to 26 Nm (19 ft. lbs.) .
Lower the vehicle.
Connect the EGR pipe to the EGR adapter.
Install the EGR pipe to the EGR adapter fasteners. Tighten the fasteners to 26 Nm (19 ft. lbs.) .
Install the stud ended generator mount bolt.
Install the accelerator control cable bracket.
Connect the vacuum hoses to the fuel regulator and to the EVAP canister purge solenoid.
NOTE: If the IAT sensor is removed, apply sealant GM P/N(NNN) NNN-NNNNor equivalent to its threads before installation.

Connect the following electrical connections:
Manifold absolute pressure sensor.
IAT sensor.
EVAP canister purge solenoid.
Fuel injector harness.
Install the air cleaner duct.
Connect the negative battery cable.

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