Sunfire L4-138 2.3L DOHC VIN D MFI (1995)
Fig. 7 Intake Manifold Installation & Bolt Tightening Sequence
1. Disconnect battery ground cable, then drain coolant to appropriate level.
2. Disconnect vacuum hose and electrical connector from MAP sensor.
3. Disconnect electrical connectors from the MAP sensor, IAT sensor, EVAP purge solenoid and fuel injector harness and position aside, then
disconnect hoses from intake manifold and hose at fuel regulator and purge solenoid to canister.
4. Disconnect air cleaner to throttle body duct.
5. Disconnect vent tube to air cleaner duct.
6. Remove throttle cable bracket, then disconnect power brake unit vacuum hose with retaining bracket to power steering bracket and position aside.
7. Disconnect coolant lines from throttle body.
8. Remove oil/air separator, leaving hoses attached to separator. Disconnect hoses from oil fill, chain housing, chain cover, intake duct and intake
manifold and remove as an assembly.
9. Remove oil fill cap and dipstick assembly, then pull oil fill tube upward to unseat from engine block.
10. Disconnect injector wiring harness connector.
11. Remove oil fill tube out top, rotating as necessary to gain clearance for oil/air separator nipple between intake tubes and fuel rail electrical harness.
12. Remove intake manifold support bracket, Fig. 6
13. Remove remaining intake manifold attaching bolts and nuts, then remove intake manifold and gasket.
14. Reverse procedure to install. Tighten intake manifold bolts in sequence shown in Fig. 7
