Parts Information and Service Procedure

PARTS INFORMATION
Dealers will be preshipped intake manifold gaskets (with no delivery charge) equivalent to 35% of their involved vehicles beginning December 16, 1993.

Additional parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). To ensure these parts will be obtained as soon as possible, they should be ordered from GMSPO on a "C.I.O." order with no special instruction code, but on an advise code (2).

Part Number Description Quantity
/Vehicle

24574409 Lower intake manifold gasket 1

SERVICE PROCEDURE

Notice:
If a vehicle has been repaired for this condition and the repair order indicates that the improved gasket (P/N 24574409) has already been installed, this procedure is not required. Proceed to step 33.

1. Disconnect negative battery cable after noting radio settings.

2. Relieve fuel pressure following procedure in applicable service manual, section 6E3-C2.

3. Remove air cleaner duct assembly and top half of air cleaner.

4. Disconnect vacuum lines from fuel pressure regulator, EGR, PCV and power brake booster.

5. For vehicles equipped with automatic transaxles, position transaxle fill tube and indicator assembly aside referring to appropriate service manual, section 7A.

6. Remove throttle cable splash shield, throttle cables and throttle cable bracket. Refer to appropriate service manual, section 6C.

7. For 1993 models, disconnect secondary ignition wiring from spark plugs and relocate ignition wiring harness.

8. Route power steering lines under air inlet blower case.

9. Loosen power steering pencil brace bolt at power steering pump and remove power steering pencil brace bolt at intake manifold. Position brace aside (do not remove from vehicle).

10. For Beretta and Corsica models, position the main engine harness which runs along the front of dash towards the top of the front of dash.

For Cavaliers, position generator harness to pulley side of power steering pump.

11. Loosen fuel line retainer under intake manifold. Refer to appropriate service manual, section 6C.

12. Remove fuel line feed hose retainer from intake manifold. Refer to appropriate service manual, section 6C.

13. Disconnect both fuel lines from intake manifold. Refer to appropriate service manual, section 6C.

14. Remove lower intake manifold nuts.

15. Remove four (4) upper intake manifold studs from cylinder head.

16. Remove intake manifold assembly from cylinder head.

17. Clean and inspect intake manifold and cylinder head mating surfaces.

Notice;
Mating surfaces must be clean and free of foreign material, grease or dirt.

Do not sand or rough up either of the mating surfaces prior to installation of new gasket.

18. Install intake manifold and gasket.

Notice:
To prevent damage to gasket, install lower intake manifold gasket against cylinder head before installing intake manifold.

Do not use additional materials or sealants to improve gasket sealing ability.

19. Install and tighten four (4) upper intake manifold studs into cylinder head. Tighten intake manifold fasteners in sequence to specifications shown in appropriate service manual, section 6A2.

20. Connect both fuel lines to intake manifold. Refer to appropriate service manual, section 6C.

21. Install fuel feed hose retainer to intake manifold. Refer to appropriate service manual, section 6C.

22. Route fuel line under fuel line retainer and tighten retainer. Refer to appropriate service manual, section 6C.

23. Route main engine wiring harness (Beretta/Corsica) or generator harness (Cavalier) to original location. Refer to appropriate service manual, section 8A.

24. Reinstall power steering pump pencil brace as follows:

- Return power steering pump pencil brace to original location.

- Install and tighten power steering pump pencil brace to intake manifold bolt.

- Tighten power steering pump pencil brace to pump bolt.

Refer to appropriate service manual, section 3B.

25. Route power steering lines to correct position.

26. For 1993 models, route and reconnect secondary ignition wiring.

27. Reinstall throttle cable splash shield, throttle cables and throttle cable bracket. Refer to appropriate service manual, section 6C.

28. For vehicles equipped with automatic transaxles, reposition transaxle fill tube and indicator assembly. Refer to appropriate service manual, section 7A.

29. Reconnect vacuum lines from fuel pressure regulator, EGR, PCV and power brake booster.

30. Reinstall air cleaner duct assembly and top half of air cleaner.

31. Reconnect negative battery cable and reset radio settings and clock.

32. Cycle ignition "ON" and "OFF" twice, waiting ten seconds between cycles, then check for fuel leaks. If any leaks are detected, repair as necessary.

33. Install Campaign Identification label.