2007 Chevrolet Optra5 LS, AutomaticFACTORY OEM SERVICE PROCEDURE

Removal Procedure

    Fig 1: Identifying Fuel Pump Fuse
    GM1289766Courtesy of GENERAL MOTORS CORP.
  1. Remove the fuel pump fuse.
  2. Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of fuel pressure.
    3. CAUTION: Refer to Battery Disconnect Caution .
  3. Disconnect the negative battery cable.
  4. Remove the air cleaner assembly.
    5. CAUTION: Refer to Safety Glasses Caution .
  5. Drain the engine coolant. Refer to Draining and Filling Cooling System .
  6. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
  7. Disconnect the purge solenoid valve connector.
  8. Disconnect the generator connector.
  9. Disconnect the A/C pressure switch connector.
  10. Disconnect the idle air control valve (IACV) connector.
  11. Disconnect the throttle position sensor (TPS) electrical connector.
  12. Disconnect the manifold air pressure (MAP) sensor electrical connector.
  13. Disconnect the oil pressure switch electrical connector.
  14. Disconnect the throttle body cable.
    15. Fig 2: View Of Upper Generator Bracket And Bolts
    GM1701490Courtesy of GENERAL MOTORS CORP.
  15. Remove the generator upper bracket.
  16. Remove the fuel injector rail and the fuel injectors.
  17. Remove the engine control module (ECM).
  18. Remove the brake vacuum hoses from the intake manifold.
  19. Disconnect the VGIS valve electrical connector.
  20. Disconnect the knock sensor electrical connector.
    21. Fig 3: Identifying Intake Manifold Support Bracket And Bolts
    GM1702008Courtesy of GENERAL MOTORS CORP.
  21. Remove the intake manifold support bracket bolts.
    22. Fig 4: Identifying Intake Manifold And Retaining Nuts Sequence
    GM1701494Courtesy of GENERAL MOTORS CORP.
  22. Remove the intake manifold retaining nuts in the sequence shown.
  23. Remove the intake manifold and gasket.
  24. Clean the sealing surfaces of the intake manifold and the cylinder head.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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