GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 1996 🢒 Firebird 🢒 Engine 🢒 Engine Cooling 🢒 Intake Manifold Replacement

Removal Procedure

    Object Number: 39907 Size: SH
  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.

    in General Information.
  2. Drain the coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
  3. Remove the throttle body air duct.
  4. Remove the wiring harness connectors from the fuel injectors.
  5. Remove the left and the right wiring harnesses and lay aside.
  6. Remove the accelerator cable clips.
  7. Remove the accelerator bracket and the accelerator cables from the throttle body.
  8. Remove the accelerator control/cruise control servo cable adjuster.
  9. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure in Engine Controls.

    10. Object Number: 39108 Size: SH
  10. Remove the secondary air injection diverter valve hoses.

    11. Object Number: 39116 Size: SH
  11. Remove the fuel pipe connectors from the fuel rail.
  12. Remove the fuel rail bolts.

    13. Object Number: 39115 Size: SH
  13. Remove the fuel pressure regulator vacuum tube.

    14. Object Number: 39116 Size: SH
  14. Remove the fuel rail from the intake manifold and lay aside.

    15. Object Number: 39903 Size: SH
  15. Remove the EGR valve vacuum harness.

    16. Object Number: 39114 Size: SH
  16. Remove the crankcase vent hose.

    17. Object Number: 39904 Size: SH
  17. Remove the exhaust gas recirculation (EGR) control valve relay nut and control valve relay.

    18. Object Number: 39905 Size: SH
  18. Remove the emission canister purge solenoid bracket nut and the solenoid.

    19. Object Number: 11454 Size: SH
  19. Remove the EGR valve nuts and the valve.
  20. Remove the EGR valve pipe nuts and the studs.

    21. Object Number: 39100 Size: SH
  21. Remove the secondary air injection pipe from the intake manifold and the right exhaust manifold.

    22. Object Number: 39906 Size: SH
  22. Remove the generator rear brace. Refer to Generator Rear Brace in Engine Electrical.

    23. Object Number: 11458 Size: SH
  23. Remove the coolant hoses from the throttle body.

    24. Object Number: 39113 Size: SH
  24. Remove the following parts:
    25. • The throttle body bolts
    • The throttle body
    • The throttle body gasket

    Object Number: 39117 Size: SH
  25. Remove the intake manifold bolts and studs.
  26. Remove the intake manifold and the gaskets.
  27. Discard the intake manifold gaskets.
  28. Clean the following parts:
    29. • The intake manifold bolts and the studs
    • The cylinder head
    • The engine block
    • The intake manifold sealing surfaces

Installation Procedure

    Object Number: 26744 Size: SH
  1. Apply a 5 mm (0.189 in) bead of RTV sealer, GM P/N 12346192 or the equivalent, to the front of the engine block. Extend the bead 13 mm (0.5 in) up each cylinder in order to the seal and retain the gaskets.

    2. Object Number: 26743 Size: SH
  2. Apply a 5 mm (0.189 in) bead of RTV sealer, GM P/N 12346192 or the equivalent, to the rear of the engine block. Extend the bead 13 mm (0.5 in) up each cylinder in order to the seal and retain the gaskets.

    3. Object Number: 39117 Size: SH
  3. Install the intake manifold with the new gaskets.

    4. Object Number: 11456 Size: SH
  4. Install the intake manifold bolts and the studs.

    5. Tighten

        • Tighten the intake manifold bolts and the studs in a first pass to 10 N·m (89 lb in) in sequence.
        • Tighten the intake manifold bolts and studs in the second pass to the final specifications of 50 N·m (37 lb ft) in sequence.

    Object Number: 39113 Size: SH
  5. Install the throttle body, gasket, and bolts.

    6. Tighten
    Tighten the throttle body bolts to 25 N·m (18 lb ft).


    Object Number: 11458 Size: SH
  6. Install the coolant hoses to the throttle body.

    7. Object Number: 39906 Size: SH
  7. Install the generator rear brace. Refer to Generator Rear Brace in Engine Electrical.

    8. Object Number: 39902 Size: SH
  8. Install the accelerator control/cruise control servo cable adjuster.
  9. Install the accelerator cable bracket, bolts, and cables.

    10. Tighten
    Tighten the accelerator cable bracket bolts to 12 N·m (106 lb in).


    Object Number: 39100 Size: SH
  10. Install the secondary air injection pipe and the nuts.

    11. Tighten
    Tighten the secondary air injection pipe exhaust manifold fitting to 55 N·m (41 lb ft).


    Object Number: 11454 Size: SH
  11. Install the EGR valve pipe studs and the nuts.
  12. Install the EGR valve and the nuts.

    13. Tighten

        • Tighten the EGR valve pipe studs to 6 N·m (53 lb in).
        • Tighten the EGR valve pipe nuts to 25 N·m (18 lb ft).
        • Tighten the EGR valve nuts to 25 N·m (18 lb ft).
        • Tighten the EGR Pipe to exhaust manifold bolt to 30 N·m (22 lb ft).

    Object Number: 39904 Size: SH
  13. Install the EGR control valve relay and the nut.

    14. Tighten
    Tighten the EGR control valve relay nut to 25 N·m (18 lb ft).


    Object Number: 39905 Size: SH
  14. Install the emission canister purge solenoid and the bracket bolt.

    15. Tighten
    Tighten the emission canister purge solenoid bracket bolt to 6 N·m (53 lb in)


    Object Number: 39116 Size: SH
  15. Install the fuel rail to the intake manifold.

    16. Object Number: 39903 Size: SH
  16. Install the fuel pressure regulator vacuum tube.

    17. Object Number: 39116 Size: SH
  17. Install the fuel rail bolts.

    18. Tighten
    Tighten the fuel rail bolts to 10 N·m (89 lb in).


    Object Number: 39108 Size: SH
  18. Install the fuel pipe connectors to the fuel rail.
  19. Install the secondary air injection diverter valve hoses.
  20. Install the left and the right wiring harnesses.

    21. Object Number: 39907 Size: SH
  21. Install the wiring harness connectors to the fuel injectors.
  22. Install the throttle body air duct.
  23. Install the negative battery cable.
  24. Refill with coolant. Refer to Cooling System Draining and Filling in Engine Cooling.