Intake Manifold Replacement Upper

Notice: The two bolts which fasten the lower intake manifold to the cylinder head are accessible only after the upper intake is removed. The bolts are located in the right front and left rear corners of the lower intake manifold. Remove the upper intake manifold to service the lower intake.

1. Disconnect the negative battery cable. Refer to

   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.

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2. Remove the air cleaner duct. Refer to Air Cleaner Element in Engine Controls.
3. Drain the engine coolant. Refer to Draining and Filling the Coolant in Engine Cooling.



4. Remove the spark plug wires on the right side of the engine.
5. Remove the acoustic engine cover. Refer to Acoustic Engine Cover Replacement .
6. Remove the canister purge solenoid electrical connector.
7. Relieve the fuel pressure. Refer to Refer to Fuel Pressure Relief in Engine Fuel.
8. Remove the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls.
9. Remove the EGR adapter to the upper intake manifold pipe. Refer to Exhaust Gas Recirculation Valve Replacement in Engine Controls.
10. Remove the throttle body. Refer to Throttle Body Assembly Replacement in Engine Controls.



11. Remove the upper intake manifold bolts.
12. Remove the upper intake manifold.
13. Remove the upper to lower intake seal.

1. Install the upper to lower intake seal.
2. Carefully install the upper intake onto the lower intake.
3. Install the upper intake manifold.
4. Apply thread lock compound GM P/N 12345382 or equivalent, to the bolt threads before assembly.
5. Install the upper intake manifold bolts.

Tighten
Tighten the bolts to 15 N·m (11 lb ft).

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.

6. Install the throttle body. Refer to Throttle Body Assembly Replacement in Engine Controls.
7. Install the EGR adapter to the upper intake manifold pipe. Refer to Exhaust Gas Recirculation Valve Replacement in Engine Controls.
8. Install the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls.
9. Install the canister purge solenoid electrical connector.
10. Install the acoustic engine cover. Refer to Acoustic Engine Cover Replacement .
11. Refill the engine coolant. Refer to Draining and Filling the Coolant in Engine Cooling.
12. Install the air cleaner duct. Refer to Air Cleaner Element in Engine Controls.
13. Connect the negative battery cable.
14. Inspect for the proper fluid levels.
15. Inspect for fluid or vacuum leaks.

Intake Manifold Replacement Lower

Notice: The two bolts which fasten the lower intake manifold to the cylinder head are accessible only after the upper intake is removed. The bolts are located in the right front and left rear corners of the lower intake manifold. Remove the upper intake manifold to service the lower intake.

1. Remove the upper intake manifold. Refer to Intake Manifold Replacement .
2. Remove the right inner fender electrical cover.
3. Remove the exhaust heat shield.
4. Remove the generator brace.
5. Remove the generator.
6. Remove the throttle body cable mounting bracket. Remove the vacuum lines. Disconnect the hoses from the vacuum lines.
7. Remove the throttle body electrical connector.
8. Remove the electrical connectors from both banks of the fuel injectors. Lay the electrical connectors aside.
9. Remove the vacuum hoses from the following locations:

•	The canister purge solenoid valve.

•	The transaxle module.

•	The intake connection.

10. Remove the vacuum hose quick connect at the upper intake manifold.
11. Remove the power steering pump. Move the pump forward. Refer to Power Steering Pump in Power Steering Gear and Pump.
12. Remove the belt tensioner mounting bracket. Refer to Drive Belt Tensioner Replacement .
13. Remove the power steering pump support bracket. Set the power steering pump aside. Refer to Power Steering Pump Replacement in Power Steering.



14. Remove the right hand spark plug wires. Set the wiring harness aside.



15. Remove the left hand spark plug wires. Set the wiring harness aside.
16. Remove the coolant bypass from the intake.
17. Remove the heater pipes from the following locations:

•	The intake

•	The front cover

18. Remove the solenoid valve mounting bracket from the intake. Remove the power steering support brace from the intake.
19. Remove the generator support brace from the intake. Refer to Generator Support Brace in Charging System.
20. Remove the upper radiator hose from the housing. Refer to Upper Radiator Hose Replacement in Cooling and Radiator.
21. Remove the thermostat housing from the intake. Refer to Thermostat Replacement in Cooling and Radiator.
22. Remove the thermostat from the intake.
23. Remove the temperature sensor electrical connector. Remove the sensor.
24. Remove the electrical connector from the temperature sensor switch at the intake.
25. Remove the lower intake manifold bolts.



26. Remove the lower intake manifold.
27. Remove the intake gaskets and seals.
28. If removing the upper intake manifold, use the following procedure:

28.1.

Remove the fuel rail and injectors from the manifold. Refer to Fuel Injection Fuel Rail Assembly Replacement .

28.2.

Remove the coolant sensor switch.

28.3.

Remove the manifold end cap cover.

29. Inspect the flatness of inlet flanges.
30. Clean the engine block.
31. Clean the cylinder block, heads, and the intake manifold sealing surface of all with a suitable solvent.
32. Clean the intake manifold bolts and bolt holes of adhesive compound.
33. Install the manifold end cap cover.
34. Install the coolant sensor switch. Refer to Coolant Sensor in Engine Cooling.
35. Install the fuel injectors and rail to the manifold. Refer to Fuel Injection Fuel Rail Assembly Replacement .

1. Apply sealer GM P/N 12345336 or equivalent to the ends of the intake manifold seals.
2. Install the lower intake manifold gaskets and seals.

Notice: The two bolts which fasten the lower intake manifold to the cylinder head are accessible only after the upper intake is removed. The bolts are located in the right front and left rear corners of the lower intake manifold. Remove the upper intake manifold to service the lower intake.

3. Install the lower intake manifold. Apply thread lock compound GM P/N 12345382 or equivalent to the two hidden bolts and ensure they are installed.

Tighten
Tighten the bolts in sequence to 10 N·m (89 lb in).

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.

4. Install the electrical connector to the temperature sensor switch at the intake.
5. Install the temperature sensor. Install the electrical connector.
6. Install the thermostat.
7. Install a new gasket to the thermostat housing.
8. Install the thermostat housing. Refer to Thermostat Replacement in Engine Cooling.
9. Install the generator support brace to the intake. Refer to Generator Support in Cooling and Radiator.
10. Install the solenoid valve mounting bracket to the intake.
11. Install the power steering support brace to the intake.
12. Install the heater pipes to the intake. Install the heater pipes to the front cover.
13. Install the coolant bypass hose to the intake.
14. Install the power steering pump support bracket. Refer to Power Steering in Power Steering Gear and Pump.
15. Install the power steering pump support bracket bolts.

Tighten
Tighten the bolts to 50 N·m (37 lb ft).




16. Position the wiring harness for installation.
17. Connect the left hand spark plug wires.



18. Connect the right hand spark plug wires.
19. Install the drive belt tensioner mounting bracket. Refer to Drive Belt Tensioner Replacement .
20. Install the power steering pump. Refer to Power Steering Pump Replacement in Power Steering.
21. Install the canister purge solenoid valve to the valve and transaxle module. Install the vacuum hoses to the valve and the transaxle module.
22. Install the electrical connectors to both sides of the fuel injectors.
23. Install the electrical connectors to the throttle body.
24. Install the generator brace. Install the generator. Refer to Generator Brace in Charging System.
25. Install the vacuum hose quick connect at the upper intake.
26. Install the throttle body mounting bracket. Install the throttle body mounting bracket bolts.

Tighten
Tighten the bolts to 4 N·m(35 lb in).

27. Install the vacuum lines. Connect the hoses to the vacuum lines.
28. Install the crossover pipe heat shield.
29. Connect the cables to the throttle body.
30. Connect the fuel lines to the fuel rail and the mount bracket.
31. Install the inner fender electrical cover.
32. Install the upper intake manifold. Refer to Intake Manifold Replacement .