GM Service Manual Online
For 1990-2009 cars only

Removal Procedure

  1. Open the hood.
  2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.
  3. Raise the vehicle by its full height. Refer to Lifting and Jacking the Vehicle.
  4. Drain the cooling system. Refer to Cooling System Draining and Filling.

  5. Object Number: 2026538  Size: SH
  6. Remove the 2 intake manifold brace bolts (2, 3).
  7. Remove and disconnect the wiring harness plug of the heated oxygen sensor 1.
  8. Remove the intake manifold brace (1).
  9. Lower the vehicle by its full height.

  10. Object Number: 2028169  Size: SH
  11. Disconnect wiring harness plug.
  12. Disconnect the pipes from the evaporative emission canister purge solenoid valve (1).
  13. Remove the evaporative emission canister purge solenoid valve (1) and the rubber mounting from the intake manifold (2).
  14. Remove the positive crankcase ventilation tube. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement.
  15. Remove the throttle body assembly. Refer to Throttle Body Assembly Replacement.
  16. Disconnect the manifold absolute pressure sensor wiring harness plug. Refer to Manifold Absolute Pressure Sensor Replacement.
  17. Remove the engine management wiring harness and the fuel injectors wiring harness.

  18. Object Number: 2028209  Size: SH
  19. Remove the 2 evaporative emission canister purge solenoid valve bracket bolts (2).
  20. Remove the evaporative emission canister purge solenoid valve bracket (1) from the intake manifold (7).
  21. Remove the 2 multiport fuel injection fuel rail bolts (3).
  22. Remove the multiport fuel injection fuel rail (4) and the fuel injectors (5) from the intake manifold (7).
  23. Remove the 4 multiport fuel injector seals (6).
  24. Remove the manifold absolute pressure sensor. Refer to Manifold Absolute Pressure Sensor Replacement.

  25. Object Number: 1944890  Size: SH
  26. Disconnect the booster vacuum pipe (1) from the intake manifold.

  27. Object Number: 2026837  Size: SH
  28. Remove the 7 intake manifold bolts (1).
  29. Remove the intake manifold (2).

Cleaning and Inspection Procedure

Clean and Inspect the intake manifold. Refer to Intake Manifold Cleaning and Inspection.

Installation Procedure

  1. Clean the sealing surfaces.
  2. Install the NEW gasket.
  3. Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 2026837  Size: SH
  4. Install the intake manifold (2) and the 7 intake manifold bolts (1) and tighten to 20 N·m (15 lb ft).

  5. Object Number: 1944890  Size: SH
  6. Connect the booster vacuum pipe (1) to the intake manifold.
  7. Install the manifold absolute pressure sensor. Refer to Manifold Absolute Pressure Sensor Replacement.

  8. Object Number: 2028209  Size: SH
  9. Install the 4 multiport fuel injector seals (6).
  10. Install the multiport fuel injection fuel rail (4) and the fuel injectors (5) to the intake manifold (7).
  11. Caution: Refer to Fastener Caution in the Preface section.

  12. Install the 2 multiport fuel injection fuel rail bolts and tighten to 8 N·m (71 lb in).
  13. Install the evaporative emission canister purge solenoid valve bracket (1) to the intake manifold (7).
  14. Install the 2 evaporative emission canister purge solenoid valve bracket bolts (2) and tighten to 8 N·m (71 lb in).
  15. Install the engine management wiring harness.
  16. Connect the manifold absolute pressure sensor wiring harness plug. Refer to Manifold Absolute Pressure Sensor Replacement.
  17. Install the throttle body assembly. Refer to Throttle Body Assembly Replacement.
  18. Install the positive crankcase ventilation tube. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement.

  19. Object Number: 2028169  Size: SH
  20. Install the evaporative emission canister purge solenoid valve (1) and the rubber mounting to the intake manifold (2).
  21. Connect the pipes to the evaporative emission canister purge solenoid valve (1).
  22. Connect wiring harness plug.
  23. Raise the vehicle by its full height.

  24. Object Number: 2026538  Size: SH
  25. Install the intake manifold brace (1).
  26. Install and disconnect the wiring harness plug of the heated oxygen sensor 1.
  27. Install the 2 intake manifold brace bolts (2; 3) and tighten to 8 N·m (71 lb in).
  28. Lower the vehicle by its full height.
  29. Fill the cooling system. Refer to Cooling System Draining and Filling.
  30. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.
  31. Close the hood.