How to Replace the Intake Manifold in a Geo Metro

The Geo Metro was plagued by a number of lemons, the model does have its loyal fans. The "roller skate" design is well known for fuel economy, pep and reliability, and many owners opted for the Metro a second time. Chevy discontinued the Geo Metro in 2000. Follow these steps for the removal and installation of the intake manifold on models produced between 1985 and 2000.

Instructions

Remove the Intake Manifold

1

Relieve the pressure in the fuel system on fuel-injected models. Disconnect the negative battery cable and drain the coolant from the cooling system (see Warnings).

2

Remove the air cleaner assembly then label and disconnect the electrical connectors from the manifold. Label and fuel return and feed hoses and disconnect them.

3

Take the water hoses from the throttle body and the intake manifold. Tag all vacuum hoses and remove them from the intake manifold.

4

Pull the PCV hose from the cylinder head cover. Take the accelerator cable from the throttle body (or the carburetor). Remove any other hoses or lines that impeded access to the intake manifold.

5

Loosen and remove the bolts that hold the intake manifold in place. Lift the manifold with the throttle body (or carburetor) from the cylinder head.

6

Clean the mating surfaces with solvent. Check the surfaces for damage.

Install the Intake Manifold

7

Use a new gasket and install the intake manifold on the cylinder head. Install the clamps and then tighten the intake manifold bolts to 17 foot pounds.

8

Reconnect all the vacuum hoses and water hoses. Connect the fuel feed and return hoses and then install the electrical lead wires.

9

Connect the air intake hose from the intercooler to the throttle body (on turbocharged models). Reconnect the accelerator cable to the carburetor.

10

Put the air clean assembly back in position. Fill the cooling system with the appropriate type and amount of coolant.

11

Reconnect the negative battery cable. Start the engine and check for vacuum leaks.