GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Buick 🢒 2007 🢒 Rendezvous - FWD 🢒 Engine 🢒 Engine Mechanical - 3.5L 🢒 Upper Intake Manifold Replacement

Removal Procedure

    Object Number: 1641072 Size: SH
  1. Drain the cooling system. Refer to Cooling System Draining and Filling .
  2. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .
  3. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  4. Disconnect the evaporative emission (EVAP) canister purge solenoid valve quick connect fitting. Refer to Plastic Collar Quick Connect Fitting Service .
  5. Remove the positive crankcase ventilation (PCV) fresh air tube from the rocker cover.

    6. Object Number: 1641077 Size: SH
  6. Reposition the brake booster vacuum hose clamp at the intake manifold.
  7. Remove the brake booster vacuum hose from the intake manifold.

    8. Object Number: 1641064 Size: SH
  8. Disconnect the electronic control module electrical connector.

    9. Object Number: 1641076 Size: SH
  9. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.

    10. Object Number: 1641065 Size: SH
  10. Remove the engine harness clip (1) from PCV foul air clip.
  11. Disconnect the exhaust gas recirculation (EGR) valve electrical connector (2).
  12. Disconnect the EVAP canister purge solenoid valve electrical connector (3).

    13. Object Number: 1641068 Size: SH
  13. Remove the engine harness clips from the intake manifold.

    14. Object Number: 1641070 Size: SH
  14. Disconnect the spark plug wires from the ignition coil.
  15. Remove spark plug wire harness clips from the following:
    16. • Ignition coil bracket
    • Spark plug wire support
    • Coolant bypass pipe
  16. Disconnect the spark plug wires from the spark plugs.

    17. Object Number: 1640582 Size: SH
  17. Remove the PCV foul air tube bolt.
  18. Remove the PCV foul air tube clip.
  19. Remove the PCV foul air tube.
  20. Remove the thermostat bypass pipe. Refer to Thermostat Bypass Pipes Replacement .
  21. Remove the ignition coil. Refer to Ignition Coil Replacement .
  22. Remove the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement .
  23. Remove the generator bracket. Refer to Generator Bracket Replacement .

    24. Object Number: 1641078 Size: SH
  24. Remove the upper intake manifold bolts and stud.
  25. Remove the spark plug support bracket.
  26. Remove the upper intake manifold.

    27. Object Number: 1641088 Size: SH
  27. Remove the upper intake manifold to lower intake manifold gaskets.
  28. Clean the upper and lower intake gasket mating surfaces.

    29. Object Number: 1641079 Size: SH
  29. If replacing the upper intake manifold, perform the following steps, remove the EVAP canister purge solenoid valve bolt.
  30. Remove the EVAP canister purge solenoid valve and insulator.

    31. Object Number: 1641081 Size: SH
  31. Remove the throttle body bolts.
  32. Remove the throttle body.
  33. Remove and inspect the throttle body seal, replace as necessary.

    34. Object Number: 1641082 Size: SH
  34. Remove the MAP sensor bolt.
  35. Remove the MAP sensor bracket and sensor.
  36. Remove and inspect the throttle body seal, replace as necessary.

Installation Procedure

    Object Number: 1641082 Size: SH
  1. If the intake manifold was replaced perform the following steps, if not proceed to step 10.
  2. Install the MAP sensor seal.
  3. Install the MAP sensor bracket and sensor.

    4. Notice: Refer to Fastener Notice in the Preface section.

  4. Install the MAP sensor bolt.

    5. Tighten
    Tighten the bolt to 10 N·m (89 lb in).


    Object Number: 1641081 Size: SH
  5. Install the throttle body seal.
  6. Install the throttle body.
  7. Install the throttle body bolts.

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


    Object Number: 1641079 Size: SH
  8. Position the EVAP canister purge solenoid valve insulator and valve to the intake.
  9. Install the EVAP canister purge solenoid valve bolt.

    10. Tighten
    Tighten the bolt to 12 N·m (106 lb in).


    Object Number: 1641088 Size: SH
  10. Install NEW upper intake manifold to lower intake manifold gaskets.

    11. Object Number: 1641078 Size: SH
  11. Install the upper intake manifold.
  12. Apply threadlock to the upper intake manifold bolt threads. Refer to Adhesives, Fluids, Lubricants, and Sealers for the correct part number.
  13. Install the spark plug support bracket onto one bolt, install the bolt.
  14. Install the other upper intake manifold bolts and stud.

    15. Tighten
    Tighten the bolts/stud to 25 N·m (18 lb ft).


    Object Number: 1640582 Size: SH
  15. Install the generator bracket. Refer to Generator Bracket Replacement .
  16. Install the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement .
  17. Install the ignition coil. Refer to Ignition Coil Replacement .
  18. Install the thermostat bypass pipe. Refer to Thermostat Bypass Pipes Replacement .
  19. Install the PCV foul air tube.
  20. Position the PCV foul air tube clip.
  21. Install the PCV foul air tube bolt.

    22. Tighten
    Tighten the bolt to 10 N·m (89 lb in).


    Object Number: 1641070 Size: SH
  22. Connect the spark plug wires to the ignition coil.
  23. Install spark plug wire harness clips to the following:
    24. • Ignition coil bracket
    • Spark plug wire support
    • Coolant bypass pipe
  24. connect the spark plug wires to the spark plugs.

    25. Object Number: 1641068 Size: SH
  25. Install the engine harness clips to the intake manifold.

    26. Object Number: 1641065 Size: SH
  26. Connect the EVAP canister purge valve electrical connector (3).
  27. Connect the EGR valve electrical connector (2).
  28. Install the engine harness clip (1) to PCV foul air clip.

    29. Object Number: 1641076 Size: SH
  29. Connect the MAP sensor electrical connector.

    30. Object Number: 1641064 Size: SH
  30. Connect the electronic control module electrical connector.

    31. Object Number: 1641077 Size: SH
  31. Install the brake booster vacuum hose to the intake manifold.
  32. Position the brake booster vacuum hose clamp at the intake manifold.

    33. Object Number: 1641072 Size: SH
  33. Install the PCV fresh air tube to the rocker cover.
  34. Connect the EVAP canister purge solenoid valve quick connect fitting. Refer to Plastic Collar Quick Connect Fitting Service .
  35. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  36. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .
  37. Fill the cooling system. Refer to Cooling System Draining and Filling .