GM Service Manual Online
For 1990-2009 cars only

Removal Procedure

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cable.
  2. Remove the intake plenum. Refer to Intake Plenum Replacement .
  3. Relieve the fuel system pressure.

  4. Object Number: 345360  Size: SH
  5. Remove the fuel supply hose from the fuel rail.
  6. Remove the fuel return hose from the fuel rail.
  7. Disconnect the fuel injector electrical harness connector.
  8. Disconnect the fuel pressure regulator vacuum connection.

  9. Object Number: 158564  Size: SH
  10. Remove the intake manifold bolts.
  11. Remove the intake manifold.
  12. Important: Mask off the ports to the intake manifold spacer. Severe damage may result if foreign objects enter the engine.

    Do not damage the machined aluminum surfaces or improper sealing may occur.

  13. Clean the intake manifold sealing surfaces with a nonabrasive tool or solvent.

Installation Procedure

  1. Remove masking from the intake ports.

  2. Object Number: 158564  Size: SH
  3. Install the intake manifold.
  4. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  5. Install the intake manifold bolts.
  6. Tighten
    Tighten the intake manifold bolts to 20 N·m (15 lb ft).

  7. Connect the fuel pressure regulator vacuum connection.
  8. Connect the fuel injector electrical harness connector.

  9. Object Number: 345360  Size: SH
  10. Install the fuel supply hose.
  11. Important: Counterhold the connections to prevent damage to the fuel rail.

    Tighten
    Tighten the fuel supply hose connections to 15 N·m (11 lb ft).

  12. Install the fuel return hose.
  13. Important: Counterhold the connections to prevent damage to the fuel rail.

    Tighten
    Tighten the fuel return hose connections to 15 N·m (11 lb ft).

  14. Install the intake plenum. Refer to Intake Plenum Replacement .
  15. Connect the negative battery cable.
  16. Reprogram the applicable accessories. Refer to Reprogramming Accessories After Battery Disconnect in Engine Electrical.