GM Service Manual Online
For 1990-2009 cars only

Removal Procedure

    Warning: Refer to Battery Disconnect Warning in the Preface section.


    Object Number: 1758512  Size: SH
  1. Disconnect the negative battery cable.
  2. Drain the engine coolant. Refer to Cooling System Draining and Filling.
  3. Disconnect the intake air temperature (IAT) sensor connector.
  4. Loosen the clamp and disconnect the air cleaner outlet hose from the electronic throttle body with resonator attached.

  5. Object Number: 1758655  Size: SH
  6. Disconnect the electronic throttle control (ETC) sensor connector.
  7. Disconnect the manifold absolute pressure (MAP) sensor connector.
  8. Disconnect the coolant hoses from the electronic throttle body.
  9. Disconnect all of the necessary vacuum hoses, including the brake booster vacuum hose at the intake manifold.

  10. Object Number: 1758559  Size: SH
  11. Remove the generator upper bracket.
  12. Remove the generator-to-intake manifold strap bracket bolt on the intake manifold and loosen the bolt on the generator.

  13. Object Number: 1758575  Size: SH
  14. Remove the fuel rail assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement.

  15. Object Number: 1758561  Size: SH
  16. Remove the evaporative (EVAP) emission canister purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement.

  17. Object Number: 1765841  Size: SH
  18. Remove the intake manifold support bracket bolt at the engine block and the intake manifold.
  19. Remove the intake manifold support bracket.
  20. Remove the ground terminal retaining bolt.

  21. Object Number: 1758657  Size: SH
  22. Remove the intake manifold retaining bolt and nuts in the sequence shown.
  23. Remove the intake manifold.
  24. Remove the intake manifold gasket.
  25. Clean the sealing surfaces of the intake manifold and the cylinder head.

Installation Procedure


    Object Number: 1758659  Size: SH
  1. Install a new intake manifold gasket.
  2. Install the intake manifold.
  3. Caution: Refer to Fastener Caution in the Preface section.

  4. Install the intake manifold retaining bolt and nuts in the sequence shown and tighten to 22 N·m (16 lb ft).

  5. Object Number: 1765841  Size: SH
  6. Install the ground wiring terminal retaining bolt to the intake manifold.
  7. Install the intake manifold support bracket and tighten bolts and cylinder block to 25 N·m (18 lb ft).

  8. Object Number: 1758571  Size: SH
  9. Install the generator upper bracket and tighten:
  10. • retaining bolts (1) to 25 N·m (18 lb ft)
    • bolt (2) to 35 N·m (26 lb ft)
  11. Install the generator-to-intake manifold strap bracket and tighten:
  12. • retaining bolt (3) to 35 N·m (26 lb ft)
    •  bolt (4) to 25 N·m (18 lb ft)

    Object Number: 1758575  Size: SH
  13. Install the fuel rail assembly and tighten bolts to 25 N·m (18 lb ft). Refer to Fuel Injection Fuel Rail Assembly Replacement.

  14. Object Number: 1758561  Size: SH
  15. Install the EVAP emission canister purge solenoid valve and tighten bolt to 5 N·m (44 lb in).

  16. Object Number: 1758655  Size: SH
  17. Connect all of the necessary vacuum lines those were previously disconnected.
  18. Connect the MAP sensor connector.
  19. Connect the ETC sensor connector.
  20. Connect the coolant hoses to the electronic throttle body.

  21. Object Number: 1758512  Size: SH
  22. Connect the air cleaner outlet hose to the electronic throttle body with resonator attached.
  23. Connect the IAT sensor connector.
  24. Connect the negative battery cable.
  25. Refill the engine cooling system. Refer to Cooling System Draining and Filling.