GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Oldsmobile 🢒 2002 🢒 Intrigue 🢒 Engine 🢒 Engine Mechanical - 3.5L 🢒 Intake Manifold Replacement

Removal Procedure
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Remove the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls - 3.5L.
  3. Partially drain the engine cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.

    4. Object Number: 289500 Size: SH
  4. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
  5. Remove the throttle and the cruise control cables with the mounting bracket from the throttle body. Refer to Accelerator Control Cable Bracket Replacement in Engine Controls - 3.5L
  6. Remove the throttle body coolant hoses from the throttle body. Refer to Throttle Body Heater Inlet Hose Replacement and Throttle Body Heater Outlet Hose Replacement in Engine Cooling.

    7. Object Number: 293967 Size: SH
  7. Remove the fuel lines from the fuel rail. Refer to Fuel Pressure Relief and Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service in Engine Controls - 3.5L.

    8. Object Number: 293966 Size: SH
  8. Remove the fuel vapor line from the EVAP canister purge solenoid.

    9. Object Number: 293968 Size: SH
  9. Remove the brake booster vacuum hose from the brake booster.
  10. Remove the A/C vacuum hose from the intake manifold.
  11. Remove the surge tank inlet pipe retainer from the fuel injector rail.
  12. Disconnect the electrical connectors from the following components:
    13. • Fuel injectors
    • Throttle position (TP) sensor
    • Idle air control (IAC) valve
    • EVAP canister purge solenoid
    • Manifold absolute pressure (MAP) sensor
  13. Remove the engine wiring harness channel bolts from the camshaft covers.
  14. Remove and set aside the engine wiring harness and channel.

    15. Object Number: 235254 Size: SH
  15. Remove the fuel pressure regulator vacuum tube (1) from the regulator (2) and the throttle body (3).

    16. Object Number: 679777 Size: SH
  16. Remove the PCV valve and the vacuum hoses (1, 2) from the camshaft covers and the intake manifold.

    17. Object Number: 576171 Size: SH
  17. Remove the EGR valve outlet pipe bolts from the intake manifold and the water crossover.
  18. Remove the EGR valve outlet pipe.
  19. Remove the fuel rail assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls - 3.5L.

    20. Object Number: 520848 Size: SH
  20. Remove the intake manifold bolts.

    21. Object Number: 287926 Size: SH
  21. Remove the throttle body coolant hose from the water crossover feed tube (1).

    22. Object Number: 679782 Size: SH
  22. Remove the intake manifold.

    23. Important: If you are replacing the intake manifold perform the following steps.

  23. Disassemble the intake manifold. Refer to Intake Manifold Disassemble in Engine Mechanical - 3.5L Unit Repair.
  24. Clean and inspect the intake manifold. Refer to Intake Manifold Cleaning and Inspection in Engine Mechanical - 3.5L Unit Repair.
  25. Assemble the intake manifold. Refer to Intake Manifold Assemble in Engine Mechanical - 3.5L Unit Repair.

Installation Procedure

    Object Number: 679782 Size: SH
  1. Install the intake manifold.

    2. Object Number: 287926 Size: SH
  2. Install the throttle body heater hose to the water crossover feed tube (1).
  3. Install the hose clamp.

    4. Object Number: 520848 Size: SH

    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.

    Important: Tighten the intake manifold bolts in circular pattern starting from the center and moving outward.

  4. Install the intake manifold bolts.

    5. Tighten
    Tighten the bolts to 7 N·m (62 lb in).

  5. Inspect the fuel injector O-rings (2) for misalignment or damage. Replace the O-rings if necessary.
  6. Install the fuel rail assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls - 3.5L.

    7. Object Number: 576171 Size: SH
  7. Install the EGR outlet pipe.
  8. Install the EGR outlet pipe to intake manifold bolts.

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

  9. Install the EGR outlet pipe to water crossover bolts.

    10. Tighten
    Tighten the bolts to 24 N·m (18 lb ft).


    Object Number: 679777 Size: SH
  10. Install the vacuum hoses (1,2) and the PCV valve to the camshaft covers and the intake manifold.

    11. Object Number: 293968 Size: SH
  11. Install the brake booster vacuum hose to the brake booster.

    12. Object Number: 235254 Size: SH
  12. Install the fuel pressure regulator vacuum tube (1) to the regulator (2) and the throttle body (3).
  13. Install the A/C vacuum hose to the intake manifold.
  14. Install the engine wiring harness and channel.
  15. Install the engine wiring harness channel bolts to the camshaft covers.

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

  16. Connect the surge tank inlet pipe retainer to the fuel injector rail.
  17. Connect the electrical connectors to the following components:
    18. • Throttle position (TP) sensor
    • Idle air control (IAC) valve
    • EVAP canister purge solenoid
    • Manifold absolute pressure (MAP) sensor
    • Fuel injectors
  18. Install the throttle body coolant hoses to the throttle body. Refer to Throttle Body Heater Inlet Hose Replacement and Throttle Body Heater Outlet Hose Replacement in Engine Cooling.
  19. Install the throttle and the cruise control cables with the mounting bracket to the throttle body. Refer to Accelerator Control Cable Bracket Replacement in Engine Controls - 3.5L.

    20. Object Number: 293967 Size: SH
  20. Install the fuel lines to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service in Engine Controls - 3.5L.

    21. Object Number: 293966 Size: SH
  21. Connect the fuel vapor line to the EVAP canister purge solenoid.
  22. Install the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls - 3.5L.

    23. Object Number: 289500 Size: SH
  23. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
  24. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  25. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.