Intake Manifold Replacement Upper
Removal Procedure
Important: This engine uses a sequential multiport fuel injection system. Connect
the injector wiring harness connectors to their appropriate fuel injector
or exhaust emissions and engine performance may be seriously affected. For
the correct injector wiring harness connector-to-fuel injector connection
procedure, refer to Engine Controls.
- Disconnect the battery ground (negative) cable. Refer to
Battery Negative Cable Disconnection and Connection
in Engine Electrical.
- Remove the throttle body assembly and the accelerator controls
cable bracket. Refer to
Throttle Body Assembly Replacement
in Engine Controls.
- Disconnect the left hand spark plug wires. Refer to
Spark Plug Wire Harness Replacement
in Engine
Electrical.
- Disconnect the wiring harness attachment clips.
• | Camshaft position (CMP) sensor wiring harness. |
• | Left hand spark plug wire harness. |
- Remove the ignition coil bracket with the coils, the purge solenoid
and the vacuum canister solenoid. Refer to
Ignition Control Module Replacement
in Engine Controls.
- Disconnect the vacuum
hose at the manifold air pressure (MAP) sensor and upper intake manifold.
- Remove the manifold air pressure (MAP) sensor and the bracket.
Refer to
Manifold Absolute Pressure Sensor Replacement
in Engine
Controls.
- Disconnect the emission
control vacuum harness.
- Disconnect the vacuum hose connections from the upper intake manifold.
• | Heater and air conditioning vacuum source hose |
• | Fuel pressure regulator |
- Remove the generator brace. Refer to
Generator Brace Replacement
in Engine Electrical.
- Remove the exhaust gas
recirculation (EGR) valve and pipe. Refer to EGR Valve Replacement in Engine
Controls.
- Remove the upper intake manifold bolts and studs.
- Remove the upper intake manifold.
- Remove the upper intake
manifold gaskets.
- Clean the seal surfaces on the manifold with degreaser.
Installation Procedure
- Install the upper intake
manifold gaskets.
- Install the upper intake manifold.
- Loosely install the upper intake manifold bolts and studs.
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.
- Install the upper
intake manifold bolts and studs.
Tighten
Tighten the upper intake manifold bolts and studs to 25 N·m
(18 lb ft).
- Install the exhaust gas
recirculation (EGR) valve. Refer to EGR Valve Replacement in Engine Controls.
- Install the generator brace. Refer to
Generator Brace Replacement
in Engine Electrical.
- Connect the vacuum hose connections to the upper intake manifold.
• | Heater and air conditioning vacuum source hose |
• | Fuel pressure regulator |
- Connect the emission control
vacuum harness.
- Install the manifold air pressure (MAP) sensor and bracket. Refer
to
Manifold Absolute Pressure Sensor Replacement
in Engine
Controls.
- Connect the vacuum hose
at the manifold air pressure (MAP) sensor and the upper intake manifold.
- Install the ignition coil bracket with the coils, the purge solenoid
and the vacuum canister solenoid. Refer to
Ignition Control Module Replacement
in Engine Controls.
- Connect the wiring harness attachment clips.
• | Camshaft position (CMP) sensor wiring harness |
• | Left (front) spark plug wire harness |
- Connect the left hand spark plug wires. Refer to
Spark Plug Wire Harness Replacement
in Engine Electrical.
- Install the throttle body assembly and the accelerator controls
cable bracket. Refer to
Throttle Body Assembly Replacement
in Engine Controls.
- Connect the battery ground (negative) cable. Refer to
Battery Negative Cable Disconnection and Connection
in
Engine Electrical.
Intake Manifold Replacement Lower
Removal Procedure
Important: This engine uses a sequential multiport fuel injection system. Injector
wiring harness connectors must be connected to their appropriate fuel injector
or exhaust emissions and engine performance may be seriously affected. For
the correct injector wiring harness connector-to-fuel injector connection
procedure, refer to Engine Controls.
- Disconnect the battery ground (negative) cable. Refer to
Battery Negative Cable Disconnection and Connection
in Engine Electrical.
- Drain the engine coolant. Refer to
Cooling System Draining and Filling
in Engine Cooling.
- Remove the upper intake manifold. Refer to
Intake Manifold Replacement
.
- Remove the generator. Refer to
Generator Replacement
in Engine Electrical.
- Remove the left hand valve rocker arm cover. Refer to
Valve Rocker Arm Cover Replacement
.
- Remove the right hand valve rocker arm cover. Refer to
Valve Rocker Arm Cover Replacement
.
- Disconnect the engine
coolant temperature (ECT) wiring harness Refer to
Engine Coolant Temperature Sensor Replacement
in Engine Controls.
- Disconnect and remove
the fuel injector wiring harness. Refer to
Fuel Injection Fuel Rail Assembly Replacement
in Engine Controls.
- Disconnect and remove the manifold air pressure (MAP) wiring harness.
Refer to
Manifold Absolute Pressure Sensor Replacement
in Engine
Controls.
- Remove the fuel pipe clip
bolt.
- Remove the fuel pipe clip.
- Disconnect the fuel feed
pipe from the fuel injector rail. Refer to
Fuel Injection Fuel Rail Assembly Replacement
in Engine Controls.
- Disconnect the fuel return
pipe from the fuel injector rail. Refer to
Fuel Injection Fuel Rail Assembly Replacement
in Engine Controls.
- Remove the fuel injector
rail. Refer to
Fuel Injection Fuel Rail Assembly Replacement
in Engine Controls.
- Remove the power steering pump from the front engine cover and
reposition aside. Refer to
Power Steering Pump Replacement
in Power Steering.
- Disconnect the heater
inlet pipe with heater hose from the lower intake manifold and reposition
for access. Refer to
Heater Inlet Pipe Replacement
in HVAC.
- Disconnect the radiator inlet hose from the engine. Refer to
Radiator Inlet Hose Replacement
in Engine Cooling.
- Disconnect the thermostat
bypass hose from the thermostat bypass pipe and lower intake manifold pipe.
- Remove the lower intake
manifold bolts.
- Remove the lower intake manifold.
- Remove the lower intake
manifold gaskets and seals.
- Clean the lower intake manifold gasket and seal surfaces on the
cylinder heads and the engine block.
- Clean the gasket and seal surfaces on the lower intake manifold
with degreaser.
- Remove all the loose RTV sealer.
- Remove the engine coolant temperature (ECT) sensor. Refer to
Engine Coolant Temperature Sensor Replacement
in Engine Controls.
- Remove the water outlet
bolts.
- Remove the water outlet.
- Remove the thermostat.
Refer to
Engine Coolant Thermostat Replacement
in Engine
Cooling.
Installation Procedure
- Install the thermostat.
Refer to
Engine Coolant Thermostat Replacement
in Engine
Cooling.
- Install the water outlet.
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.
- Install the water
outlet bolts.
Tighten
Tighten the water outlet bolts to 25 N·m (18 lb ft).
- Install the engine coolant temperature (ECT) sensor. Refer to
Engine Coolant Temperature Sensor Replacement
in Engine Controls.
- Apply 8-12 mm
(0.08-0.11 in) bead of RTV Sealer, or equivalent, on each ridge
where front and rear of the lower intake manifold contact the engine block
(1).
- Install the lower intake manifold gaskets.
- Install the lower intake
manifold.
- Apply sealant, GM P/N 12345382 to the threads of the bolts.
Notice: An oil leak may result if the vertical bolts are not tightened before
the diagonal bolts.
- Hand tighten the vertical lower intake manifold bolts.
- Hand tighten the diagonal lower intake manifold bolts.
- Install the lower intake manifold bolts.
Tighten
- Tighten the vertical lower intake manifold bolts (1) to 13 N·m
(115 lb in).
- Tighten the diagonal lower intake manifold bolts (2) to 13 N·m
(115 lb in).
- Connect the thermostat
bypass hose to the thermostat bypass pipe and lower intake manifold pipe.
- Connect the radiator inlet hose to the engine. Refer to
Radiator Inlet Hose Replacement
in Engine Cooling.
- Connect the heater inlet
pipe and heater hose to the lower intake manifold. Refer to
Heater Inlet Pipe Replacement
in HVAC.
- Install the power steering pump to the front engine cover. Refer
to
Power Steering Pump Replacement
in Power Steering.
- Install the fuel injector
rail. Refer to
Fuel Injection Fuel Rail Assembly Replacement
in Engine Controls.
- Connect the fuel return
pipe to the fuel injector rail. Refer to
Fuel Injection Fuel Rail Assembly Replacement
in Engine Controls.
- Connect the fuel feed
pipe to the fuel injector rail. Refer to
Fuel Injection Fuel Rail Assembly Replacement
in Engine Controls.
- Install the fuel pipe
clip.
- Install the fuel pipe
clip bolt.
Tighten
Tighten the fuel pipe clip bolt to 8 N·m (71 lb in).
- Install and connect the
fuel injector wiring harness. Refer to
Fuel Injection Fuel Rail Assembly Replacement
in Engine Controls.
- Install and connect the manifold air pressure (MAP) wiring harness.
Refer to
Fuel Injection Fuel Rail Assembly Replacement
in Engine Controls.
- Connect the engine coolant
temperature (ECT) wiring harness. Refer to
Engine Coolant Temperature Sensor Replacement
in Engine Controls.
- Install the right hand valve rocker arm cover. Refer to
Valve Rocker Arm Cover Replacement
.
- Install the left hand valve rocker arm cover. Refer to
Valve Rocker Arm Cover Replacement
.
- Install the Generator. Refer to
Generator Replacement
in Engine Electrical.
- Install the upper intake manifold. Refer to
Intake Manifold Replacement
.
- Fill the cooling system. Refer to
Cooling System Draining and Filling
in Engine Cooling.
- Connect the battery ground (negative) cable. Refer to
Battery Negative Cable Disconnection and Connection
in
Engine Electrical.