GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2002 🢒 Tracker - 2WD 🢒 Engine 🢒 Engine Mechanical - 1.6L 🢒 Intake Manifold Replacement

Removal Procedure
  1. Remove the fuel tank filler cap in order to release the fuel vapor pressure in the fuel tank. After releasing the pressure, reinstall the filler cap.
  2. Release the fuel pressure. Refer to Fuel Pressure Relief in Engine Controls.

    3. Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  3. Disconnect the negative battery cable.
  4. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.

    5. Object Number: 466398 Size: SH
  5. Disconnect the Intake Air Temperature (IAT) Sensor.
  6. Disconnect the Mass Air Flow (MAF) Sensor.
  7. Depress the electrical harness clamps and remove the harness from the air cleaner assembly.
  8. Remove the air intake hose (7) from the throttle body.

    9. Object Number: 586497 Size: SH
  9. Remove the accelerator cable (2) from the accelerator cable bracket (1).
  10. Remove the accelerator cable from the throttle body bellcrank (3).

    11. Object Number: 586502 Size: SH
  11. Disconnect the following electrical connectors:
    12. • Throttle Position (TP) Sensor (4)
    • Idle Air Control (IAC) Valve (3)
    • Engine Coolant Temperature (ECT) Sensor (2)
    • Evaporative emission canister purge valve
  12. Remove the EVAP canister purge valve vacuum hose.
  13. Remove the EVAP canister purge valve bracket bolt.
  14. Remove the EVAP canister purge valve bracket and valve assembly.
  15. Remove the coolant hose from the throttle body (1).

    16. Object Number: 586504 Size: SH
  16. Disconnect the following electrical connectors:
    17. • Exhaust gas recirculation (EGR) connector (4)
    • Manifold absolute pressure (MAP) sensor connector (1)
    • Engine ground wire (2) from intake manifold
  17. Remove the brake booster supply hose (3) from the intake manifold.

    18. Object Number: 586505 Size: SH

    Important: Use a shop rag to catch any fuel that may leak during the disconnection of the fuel lines.

  18. Disconnect the inlet fuel line (1).
  19. Disconnect the return fuel line (2).

    20. Object Number: 466472 Size: SH
  20. Remove the upper radiator (2) hose from the thermostat housing (1).

    21. Object Number: 586494 Size: SH
  21. Remove the upper generator mounting bracket (2).

    22. Object Number: 586508 Size: SH
  22. Remove the lower intake manifold support bracket (2) from the intake manifold (1).

    23. Object Number: 586492 Size: SH
  23. Remove the two bolts and the upper front intake manifold support bracket (2) from the intake manifold.
  24. Remove the two bolts and the upper rear intake manifold support bracket (4) from the intake manifold.
  25. Remove the crankcase vent hose (1).
  26. Remove the PCV hose from the PCV valve (3).
  27. Disconnect the fuel injector 6-way connector at the rear of the intake manifold.
  28. Remove the EGR valve.
  29. Remove the following from the cylinder head:
    30. • The eight nuts
    • The three bolts
    • The intake manifold with the gasket
  30. Remove the following components from the intake manifold and transfer as required:
    31. • The ECT sensor
    • The ECT sensor sending unit
    • The throttle body
    • The fuel rail
    • The fuel injector harness
    • The MAP sensor
    • The EGR tube
    • The accelerator cable bracket

Installation Procedure
  1. Insure the following are installed to the intake manifold as required:
    2. • The EGR valve
    • The ECT sensor
    • The ECT sensor sending unit
    • The throttle body
    • The fuel rail
    • The fuel injector harness
    • The MAP sensor
    • The EGR tube
    • The accelerator cable bracket

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2. Install a new intake manifold gasket and the intake manifold to the cylinder head. Secure with 8 nuts and 3 bolts.

    3. Tighten
    Tighten the intake manifold nuts and bolts to 23 N·m (17 lb ft).


    Object Number: 586492 Size: SH
  3. Install the upper rear intake manifold support bracket (4) to the intake manifold. Secure the bracket with two bolts.

    4. Tighten
    Tighten the upper rear intake manifold support bracket bolts to 50 N·m (37 lb ft).

  4. Install the upper front intake manifold support bracket (2) to the intake manifold. Secure the bracket with 2 bolts.

    5. Tighten
    Tighten the upper front intake manifold support bracket bolts to 50 N·m (37 lb ft).

  5. Install the crankcase vent hose (1).
  6. Install the PCV hose (3) to the PCV valve.
  7. Connect the fuel injector 6-way connector at the rear of the intake manifold.

    8. Object Number: 586508 Size: SH
  8. Install the lower intake manifold support bracket (2) to the intake manifold (1). Secure the bracket with 2 bolts.

    9. Tighten
    Tighten the lower intake manifold support bracket bolts to 50 N·m (37 lb ft).


    Object Number: 586494 Size: SH
  9. Install the upper generator mounting bracket (2). Secure the bracket with two bolts.

    10. Tighten
    Tighten the upper generator mounting bracket bolts to 50 N·m (37 lb ft).

  10. Adjust the generator drive belt tension. Refer to Drive Belt Replacement .
  11. Reinstall the EVAP canister.

    12. Object Number: 466472 Size: SH
  12. Install the upper radiator hose to the thermostat housing (1).

    13. Object Number: 586505 Size: SH
  13. Install the fuel inlet hose (1) to the fuel line union.
  14. Install the fuel return hose (2) to the fuel line union.

    15. Object Number: 586504 Size: SH
  15. Connect the following electrical connectors:
    16. • Exhaust gas recirculation (EGR) connector (4)
    • Manifold absolute pressure (MAP) sensor connector (1)
    • Engine ground wire (2) from intake manifold
  16. Install the brake booster supply hose (3) to the intake manifold.

    17. Object Number: 586502 Size: SH
  17. Connect the following electrical connectors:
    18. • Throttle position (TP) sensor (4)
    • Idle air control (IAC) valve (3)
    • Engine coolant temperature (ECT) sensor (2)
    • Evaporative emission canister purge valve
  18. Install the EVAP canister purge valve vacuum hose.
  19. Install the coolant hose to the throttle body (1).

    20. Object Number: 586497 Size: SH
  20. Install the accelerator cable (2) to the accelerator cable bracket (1).
  21. Install the accelerator cable to the throttle body bellcrank (3). Adjust the accelerator cable as necessary. Refer to Accelerator Control Cable Replacement in Engine Controls.

    22. Object Number: 466398 Size: SH
  22. Connect the intake air temperature (IAT) sensor.
  23. Connect the mass air flow (MAF) sensor.
  24. Install the electrical harness clamps to the air cleaner assembly.
  25. Install the air intake pipe (7) to the throttle body.
  26. Refill the cooling system as necessary. Refer to Cooling System Draining and Filling in Engine Cooling.
  27. Connect the negative battery cable.

    28. Tighten
    Tighten the negative battery cable bolt to 15 N·m (11 lb ft).