GM Service Manual Online
For 1990-2009 cars only

Removal Procedure


    Object Number: 1201072  Size: SH
  1. Remove the cross car brace. Refer to Cross Vehicle Brace Replacement .
  2. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .

  3. Object Number: 928153  Size: SH
  4. Remove the positive crankcase ventilation (PCV) dirty air tube from the camshaft cover. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement .

  5. Object Number: 928145  Size: SH
  6. Remove the PCV fresh air tube. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement .

  7. Object Number: 928160  Size: SH
  8. Remove the sight shield bracket nuts.
  9. Remove the sight shield bracket.

  10. Object Number: 887913  Size: SH
  11. Disconnect the left side fuel injector electrical connectors (1) from the fuel injectors (2).

  12. Object Number: 887914  Size: SH
  13. Disconnect the right side fuel injector electrical connectors (1) from the fuel injectors (2).

  14. Object Number: 1239219  Size: SH
  15. Disconnect the evaporative emission (EVAP) purge valve line (2) and electrical connector (1).

  16. Object Number: 1235105  Size: SH
  17. Remove the EVAP line from the retaining feature (2) at the rear of the right head. Position the line aside.
  18. Relieve the fuel system pressure. Refer to Fuel Pressure Relief

  19. Object Number: 1234881  Size: SH
  20. Disconnect the fuel line from the fuel rail (1). Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service .
  21. Remove the fuel line from the retainer at the rear of the right head.

  22. Object Number: 948135  Size: SH
  23. Remove the fasteners attaching the fuel rail to the intake manifold.

  24. Object Number: 1234883  Size: SH
  25. Lift the entire fuel rail and injector assembly from the intake manifold.

  26. Object Number: 1234875  Size: SH
  27. Loosen the plenum duct clamp (1) at the front of the intake manifold.

  28. Object Number: 928175  Size: SH
  29. Loosen the bolts attaching the intake manifold to the cylinder heads.
  30. Remove the intake manifold by using an upward lifting motion at the rear of the manifold assembly.
  31. Inspect the intake manifold. Refer to Intake Manifold Cleaning and Inspection .

Installation Procedure

  1. Transfer the necessary parts when replacing the intake manifold. Refer to Intake Manifold Disassemble and Intake Manifold Assemble .
  2. Lightly grease the inside edge of the rubber plenum duct.

  3. Object Number: 1012862  Size: SH
  4. Ensure that the NEW gaskets are installed to the intake manifold.

  5. Object Number: 928175  Size: SH
  6. Place the intake manifold in position.
  7. Position the front of the intake manifold into the plenum duct.
  8. Position the rear of the intake manifold downward onto the cylinder heads.
  9. Loosely install the 10 bolts attaching the intake manifold to the cylinder heads.
  10. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 928179  Size: SH
  11. Tighten the intake manifold bolts in sequence (1-10).
  12. Tighten
    Tighten the intake manifold bolts to 10 N·m (89 lb in).

  13. Ensure that the plenum duct is fully attached to the front of the intake manifold.
  14. Tighten
    Tighten the plenum duct clamp to 2.25 N·m (20 lb in).

  15. Lubricate the intake manifold fuel injector bores with light mineral oil, clean engine oil or equivalent. Refer to Adhesives, Fluids, Lubricants, and Sealers for the correct part number.

  16. Object Number: 1234883  Size: SH

    Important: DO NOT force the injectors into position.

  17. Install the entire fuel rail and injector assembly into the intake manifold by pressing the fuel rail and injector simultaneously into the correct position.
  18. Install the bolts attaching the fuel rail to the intake manifold.
  19. Tighten
    Tighten the fuel rail bolts to 10 N·m (89 lb in).


    Object Number: 1234881  Size: SH
  20. Install the fuel line to the retainer at the rear of the right head.
  21. Connect the fuel line to the fuel rail (1). Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service .

  22. Object Number: 1235105  Size: SH
  23. Install the EVAP purge valve line to the retainer (2) at the rear of the right head.

  24. Object Number: 1239219  Size: SH
  25. Install the EVAP purge valve line (2) and electrical connector (1).

  26. Object Number: 887914  Size: SH
  27. Connect the right side fuel injector electrical connectors (1) to the fuel injectors (2).

  28. Object Number: 887913  Size: SH
  29. Connect the left side fuel injector electrical connectors (1) to the fuel injectors (2).

  30. Object Number: 928160  Size: SH
  31. Install the sight shield bracket.
  32. Install the sight shield bracket nuts.
  33. Tighten
    Tighten the sight shield bracket nuts to 10 N·m (89 lb in).


    Object Number: 928145  Size: SH
  34. Install the PCV fresh air tube to the engine.

  35. Object Number: 928153  Size: SH
  36. Install the PCV dirty air tube to the engine.

  37. Object Number: 1201072  Size: SH
  38. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
  39. Install the cross car brace. Refer to Cross Vehicle Brace Replacement .