GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Express - AWD 🢒 Body Hardware and Trim 🢒 Interior Trim and Paneling 🢒 Intake Manifold Tube Replacement

Intake Manifold Tube Replacement LMM

Removal Procedure

    Object Number: 1865884 Size: SH
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.
  3. Remove the engine cover. Refer to Engine Cover Replacement.
  4. Disconnect the engine harness electrical connector (1) from the manifold absolute pressure (MAP) sensor.
  5. Disconnect the engine harness electrical connector (2) from the intake air heater (IAH).
  6. Disconnect the engine harness electrical connector (3) from the intake air valve.

    7. Object Number: 1865892 Size: SH
  7. Remove the front intake manifold tube nut.
  8. Reposition the positive battery cable boot.
  9. Remove the positive battery cable nut at the IAH.
  10. Remove the positive battery cable from the IAH stud.

    11. Object Number: 1865929 Size: SH
  11. Remove the engine wiring harness clip bolt (1) at the rear of the intake manifold tube.
  12. Remove the 2 rear intake manifold tube bolts (3).
  13. Remove the rear intake manifold tube nut (2).

    14. Object Number: 1731138 Size: SH
  14. Remove the engine wiring harness clip from the intake manifold tube.
  15. Remove the engine wiring harness clip bolt (3).
  16. Remove the intake manifold tube bolts (2, 4) and nut (1).

    17. Object Number: 1865938 Size: SH
  17. Remove the intake manifold tube with the stud.
  18. Remove and discard the 2 metal EGR gaskets from the EGR valve.
  19. Remove and discard the O-ring seal from the center intake manifold.

    20. Object Number: 1865958 Size: SH
  20. If replacing the intake manifold tube perform the following steps, otherwise proceed to step 5 in the installation procedure.
  21. Remove the MAP sensor bolt.
  22. Remove the MAP sensor and bracket.

    23. Object Number: 1865972 Size: SH
  23. Remove the air intake valve bolts (1).
  24. Remove the air intake valve (2) and the IAH (3) from the intake manifold tube.

Installation Procedure

    Object Number: 1865972 Size: SH
  1. Position the IAH (3) and the air intake valve (2) to the intake manifold tube.

    2. Caution: Refer to Fastener Caution in the Preface section.

  2. Install the air intake valve bolts and tighten to 20 N·m (15 lb ft).

    3. Object Number: 1865958 Size: SH
  3. Install the MAP sensor and bracket.
  4. Install the MAP sensor bolt and tighten to 10 N·m (89 lb in).

    5. Object Number: 1865938 Size: SH
  5. Install a NEW the O-ring seal onto the center intake manifold.
  6. Install NEW metal EGR gaskets onto the EGR valve.
  7. Install the intake manifold tube with the stud and tighten to 25 N·m (18 lb ft).

    8. Object Number: 1865929 Size: SH
  8. Install the intake manifold tube bolts (2, 4) and nut (1) and tighten to 25 N·m (18 lb ft).
  9. Install the engine wiring harness clip bolt (3) and tighten to 15 N·m (11 lb ft).
  10. Install the engine wiring harness clip to the intake manifold tube.

    11. Object Number: 1731131 Size: SH
  11. Install the rear intake manifold tube nut (2) and tighten to 25 N·m (18 lb ft).
  12. Install the 2 rear intake manifold tube bolts (3) and tighten to 25 N·m (18 lb ft).
  13. Install the engine wiring harness clip bolt (1) at the rear of the intake manifold tube and tighten to 15 N·m (11 lb ft).

    14. Object Number: 1865892 Size: SH
  14. Install the positive battery cable to the IAH stud.
  15. Install the positive battery cable nut at the IAH and tighten to 10 N·m (89 lb ft).
  16. Position the positive battery cable boot.
  17. Install the front intake manifold tube nut. Tighten the bolt to 15 N·m (11 lb ft).

    18. Object Number: 1865884 Size: SH
  18. Connect the engine harness electrical connector (3) to the intake air valve.
  19. Connect the engine harness electrical connector (2) to the IAH.
  20. Connect the engine harness electrical connector (1) to the MAP sensor.
  21. Install the engine cover. Refer to Engine Cover Replacement.
  22. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.
  23. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.