Intake Manifold Replacement Upper

1. Remove the negative battery cable. Refer to

   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.

   in General Information.
2. Remove the air cleaner assembly.
3. Remove the wiring harness connectors and the brackets and move aside.
4. Remove the throttle, the cruise control linkages and the bracket (if equipped).
5. Remove the throttle body electrical connectors.
6. Remove the PCV and the hose.
7. Remove the EGR inlet tube.
8. Remove the purge solenoid and the connectors.
9. Remove the ignition coil and the bracket. Refer to Ignition Coil Replacement in Engine Electrical.
10. Remove the number 8 spark plug wire from the distributor.



11. Remove the upper intake manifold bolts.
12. Remove the upper intake manifold and the gasket.
13. Clean the excessive carbon deposits from the exhaust and the EGR passages.

1. Install the upper intake manifold gasket.
2. Install the upper intake manifold.



3. Install the upper intake manifold bolts using the following procedure:

3.1.	Coat a minimum of 8 threads of the bolts with threadlocking sealant GM P/N 12345493.

Tighten

•	Tighten the bolts in sequence to 8 N·m (72 lb in).

•	Re-tighten the bolts in sequence to 14 N·m (10 lb ft).

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. Connect the number 8 spark plug wire.
5. Install the ignition coil and the bracket. Refer to Ignition Coil Replacement in Engine Electrical.
6. Install the purge solenoid and the connectors.
7. Install the EGR inlet tube.
8. Install the PCV and the hose.
9. Connect the throttle body electrical connectors.
10. Install the throttle and the cruise control linkage and the bracket (if equipped).
11. Connect the wiring harness connectors and install the brackets.
12. Install the air cleaner assembly.
13. Connect the negative battery cable.

Intake Manifold Replacement Lower

1. Remove the upper intake manifold. Refer to Intake Manifold Replacement .
2. Remove the air conditioning lines at the A/C compressor. Refer to Heating, Ventilation and Air Conditioning.
3. Remove the distributor. Mark the relationship of the distributor housing and the rotor for proper replacement. Refer to Engine Electrical.
4. Drain the coolant. Refer to Draining and Filling Cooling System in Engine Cooling.
5. Remove the upper radiator hose at the thermostat housing. Refer to Radiator Hoses Replacement in Engine Cooling.
6. Remove the heater hose.
7. Remove the water pump bypass hose.
8. Remove the fuel line brackets and the fuel rail. Refer to Engine Controls.



9. Remove the lower intake manifold bolts.
10. Remove the lower intake manifold and the gaskets.
11. Clean old pieces of gasket from the gasket surfaces.
12. Clean excessive carbon buildup from the exhaust passages.
13. Clean scale and deposits from the coolant passages.
14. Clean excessive carbon deposits from the EGR passages.

1. Install the gaskets to the cylinder head with the THIS SIDE UP stamping facing up.
2. Install the lower intake manifold to the engine.
3. Apply the sealer Loctite 242 GM P/N 12345382 or equivalent to the lower intake manifold bolts.



4. Install the lower intake manifold bolts.

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

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.

5. Install the water pump bypass hose.
6. Install the wiring harness, connectors, and brackets.
7. Install the fuel line brackets and the fuel rail.
8. Install the heater hose.
9. Install the upper radiator hose at the thermostat housing.
10. Install the air conditioning lines to the compressor.
11. Install the distributor. Refer to Distributor Replacement in Engine Electrical.
12. Fill the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling.
13. Install the upper intake manifold. Refer to Intake Manifold Replacement .
14. Charge the A/C system. Refer to Heating, Ventilation, and Air Conditioning.