Intake Manifold Replacement Upper

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.

1. Disconnect the negative battery cable.



2. Remove the air intake duct from the throttle body. Refer to Air Cleaner Outlet Front Duct Replacement .



3. Remove the crankcase vent tube from the throttle body.
4. Remove the electrical harness bracket retaining bolts and reposition brackets and harness to provide clearance.



5. Disconnect the EGR valve electrical connector.

Remove the EGR pipe from the upper intake manifold. Refer to Exhaust Gas Recirculation Pipe Replacement .

6. Remove the EVAP canister solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement .
7. Disconnect the vacuum modulator hose.



8. Remove the upper intake manifold retaining bolts.
9. Remove the upper intake manifold and gaskets.
10. Clean the excessive carbon deposit from the exhaust and the EGR valve passages. Refer to Intake Manifold Cleaning and Inspection .

1. Install the upper intake manifold gaskets.
2. Install the upper intake manifold into position.

Important: Failure to follow the procedure listed could cause a driveability problem.

3. Coat a minimum of eight threads of the bolts with thread locking sealant GM P/N 12345493.




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.

4. Install the upper intake manifold bolts.

Tighten

1. Tighten the bolts in the sequence shown to 8 N·m (71 lb in).
2. Tighten the bolts in the sequence shown to 18 N·m (13 lb ft).



5. Install the EGR pipe to the upper intake manifold.

Tighten
Tighten the EGR valve pipe fitting to 60 N·m (44 lb ft).

6. Install the EVAP canister solenoid valve to the intake manifold. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement in Engine Controls.
7. Connect the EGR valve electrical connector.



8. Install the crankcase vent tube to the valve rocker arm cover.
9. Install the electrical harness and retaining brackets.



10. Install the air cleaner intake duct to the throttle body. Refer to Air Cleaner Outlet Front Duct Replacement in Engine Controls.

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.

11. Connect the negative battery cable.

Intake Manifold Replacement Lower

1. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.

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.

2. Disconnect the negative battery cable.



3. Remove the upper intake manifold from the lower intake manifold. Refer to Intake Manifold Replacement .
4. Remove the camshaft position sensor from the lower intake manifold. Refer to Camshaft Position Sensor Replacement in Engine Controls.
5. Remove the MAP sensor from the lower intake manifold. Refer to Manifold Absolute Pressure Sensor Replacement in Engine Controls.
6. Remove the upper radiator hose from the thermostat housing. Refer to Radiator Hose Replacement in Engine Cooling.
7. Remove the lower radiator coolant bypass hose and clamp from the lower intake manifold.
8. Remove the thermostat. Refer to Engine Coolant Thermostat Replacement in Engine Cooling.
9. Remove the coolant bypass hose and clamps from the intake manifold.
10. Relieve fuel system pressure. Refer to Fuel Pressure Relief in Engine Controls.



11. Remove the retaining bolts securing the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls.



12. Disconnect the fuel pressure and return pipes. Refer to Fuel Hose/Pipes Replacement - Chassis in Engine Controls.
13. Remove the fuel rail from the lower intake manifold. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls.
14. Disconnect the oil fill tube connector hose. Refer to Oil Level Indicator and Tube Replacement .



15. Remove the lower intake manifold retaining bolts.
16. Remove the lower intake manifold from the cylinder heads.

Important: The lower intake manifold gaskets and seals are reusable. Replace only the gaskets and seals if they are damaged.

17. Remove the lower intake manifold gaskets and seals.
18. Clean all sealing surfaces of oil and grease from the cylinder heads. Refer to Intake Manifold Cleaning and Inspection .

1. Install the lower intake manifold gaskets to the cylinder head with THIS SIDE UP stamped facing up.
2. Install the lower intake manifold to the cylinder heads.
3. Apply the Locttite® 242 GM P/N 12345382 to the lower intake manifold bolts. Coat a minimum of 8 threads.




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.

4. Install the lower intake manifold bolts to the engine head.

Tighten
Tighten the bolts in the sequence shown to 40 N·m (30 lb ft).

5. Install the MAP sensor to the lower intake manifold. Refer to Manifold Absolute Pressure Sensor Replacement in Engine Controls.
6. Connect the oil fill tube connector hose. Refer to Oil Level Indicator and Tube Replacement .



7. Install the fuel rail to the lower intake manifold. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls.



8. Install the fuel rail retaining bolts. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls .
9. Connect the fuel pressure and return pipes. Refer to Fuel Hose/Pipes Replacement - Chassis in Engine Controls.
10. Install the thermostat to the lower intake manifold. Refer to Engine Coolant Thermostat Replacement in Engine Cooling.
11. Install the coolant bypass hose and clamp.
12. Install the lower radiator coolant bypass hose and clamp to the lower intake manifold.
13. Install the radiator hose to the lower intake manifold. Refer to Radiator Hose Replacement in Engine Cooling.



14. Install the camshaft position sensor. Refer to Camshaft Position Sensor Replacement in Engine Controls.
15. Install the upper intake manifold to the lower intake manifold. Refer to Intake Manifold Replacement .
16. Refill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.

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.

17. Connect the battery negative cable.