How do you replace a lower intake manifold gasket on a 1999 Chevy Malibu?

In: Chevy Malibu

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Disconnect the Battery. First of all you must drain all the coolant from the radiator and engine. Next you will want to drain the oil and leave your drain plug oout with a drip pan under the oil pan so that when you do raise the intake any coolant left in the engine that spills into the valley will also drain out. Start by taking off your air intake tube and upper air cleaner housing. Next remove the bolts to the accelerator cable mounting bracket and the lower net on the throttle body that holds the coolant line in place. Remove the 6mm bolt from the coolant bleed housing on the front left of the engine. Remove both quick connect heater hose connectors. take off the metal overflow line from the coolant resevoir to the thermostat housing. remove the coolant tube that crosses over the front valve cover and goes to the heater hose. Remove the 2 bolts that hold the EGR to the EGR exhaust tube and upper intake, remove the EGR. Next take off the serpentine belt. Put a jack (with a 2x4 on it) under the oil pan and remove the front motor mount(The one closest to the passenger fender on the top.) Remove the 3 bolts that hold the power steering pump in place and remove the power steering lines(one rubber and one steel).Remove pump. Now remove the 3 bolts that hold the alternator in place and put the alternator aside. Take the two valve covers off by taking the 4 bolts out of each one. Remove the plenum(upper intake) by removing the 6 bolts. Remove the 6mm bolts that hold the fuel rail to the lower intake. Taking caution lift the injectors and the fuel rail from the lower intake after disconnecting the electrical plug for the harness. Remove the bolts for the lower intake in oppisite sequence of torquing them down. Remove the lower intake manifold. Hopefully I didnt forget anything. replace gasket and reverse directions for installing. Dont forget to torque the lower intake in sequence and to manufacturers tourque specifications.

First answer by Mtrheddman. Last edit by Mtrheddman. Contributor trust: 59 [recommend contributor]. Question popularity: 24 [recommend question]

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