GM Service Manual Online
For 1990-2009 cars only

Removal Procedure


    Object Number: 1608799  Size: SH
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  2. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement.
  3. Drain the cooling system. Refer to Cooling System Draining and Filling.
  4. Remove the positive crankcase ventilation (PCV) fresh air tube. Refer to Plastic Collar Quick Connect Fitting Service.

  5. Object Number: 1608801  Size: SH
  6. Remove the PCV foul air tube. Refer to Plastic Collar Quick Connect Fitting Service.

  7. Object Number: 1608820  Size: SH
  8. Remove the vacuum hose from the intake manifold.

  9. Object Number: 1608325  Size: SH
  10. Reposition the heater inlet and outlet hose/pipe clamps at the engine pipes.
  11. Remove the heater inlet and outlet hose/pipe clamp nuts from the throttle body studs.
  12. Remove the heater inlet and outlet hoses/pipes from the engine pipes and the throttle body studs.
  13. Reposition the hoses/pipes out of the way.

  14. Object Number: 1608869  Size: SH
  15. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (1).
  16. Disconnect the BARO sensor electrical connector.

  17. Object Number: 1608290  Size: SH
  18. Disconnect the evaporative emission (EVAP) canister purge solenoid electrical connector (1).
  19. Disconnect the chassis EVAP line quick connect fitting from the purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service.
  20. Disconnect the electronic throttle control (ETC) electrical connector (2).

  21. Object Number: 1608802  Size: SH
  22. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.
  23. Disconnect the left side spark plug wires from the spark plugs.
  24. Disconnect the left side spark plug wires from the ignition coil.
  25. Disengage the spark plug wire retainer clips from the intake manifold bracket and the heater inlet/outlet hose/pipe bracket.
  26. Remove the left side spark plug wires.

  27. Object Number: 1608805  Size: SH
  28. Remove the throttle body bolts and nuts.
  29. Remove the throttle body and gasket.

  30. Object Number: 1608810  Size: SH
  31. Remove the EVAP canister purge solenoid valve bolt.
  32. Remove the EVAP canister purge solenoid valve.

  33. Object Number: 1608814  Size: SH
  34. Remove the MAP sensor bracket bolts.
  35. Remove the MAP sensor bracket and sensor.

  36. Object Number: 1608816  Size: SH
  37. Remove the ignition coil bracket-to-intake manifold bolts.
  38. Remove the intake manifold cover ball stud nut from the intake manifold stud.
  39. Remove the upper intake manifold bolts and stud.
  40. Separate and remove the upper intake manifold from the lower intake manifold.
  41. Remove the upper to lower intake manifold gaskets.
  42. Clean the upper intake to lower intake gasket mating surfaces.

Installation Procedure


    Object Number: 1608816  Size: SH
  1. Install NEW upper to lower intake manifold gaskets.
  2. Install the upper intake manifold onto the lower intake manifold.
  3. Apply threadlock to the upper intake manifold bolts/stud threads. Refer to Adhesives, Fluids, Lubricants, and Sealers.
  4. Caution: Refer to Fastener Caution in the Preface section.

  5. Install the upper intake manifold bolts and stud.
  6. Tighten
    Tighten the bolts and stud to 25 N·m (18 lb ft).

  7. Install the intake manifold cover ball stud nut to the intake manifold stud.
  8. Tighten
    Tighten the nut to 5 N·m (44 lb in).

  9. Install the ignition coil bracket-to-intake manifold bolts.
  10. Tighten
    Tighten the bolts to 25 N·m (18 lb ft).


    Object Number: 1608814  Size: SH
  11. Install the MAP sensor and bracket.
  12. Install the MAP sensor bracket bolts.
  13. Tighten
    Tighten the bolts to 25 N·m (18 lb ft).


    Object Number: 1608810  Size: SH
  14. Install the EVAP canister purge solenoid valve.
  15. Install the EVAP canister purge solenoid valve bolt.
  16. Tighten
    Tighten the bolts to 16 N·m (12 lb ft).


    Object Number: 1608805  Size: SH
  17. Inspect the throttle body seal for damage, replace as necessary.
  18. Apply threadlock to the throttle body bolts/studs threads. Refer to Adhesives, Fluids, Lubricants, and Sealers.
  19. Position the throttle body gasket and throttle body to the intake.
  20. Install the throttle body bolts and nuts.
  21. Tighten
    Tighten the bolts/studs to 10 N·m (89 lb in).


    Object Number: 1608802  Size: SH
  22. Install the left side spark plug wires.
  23. Engage the spark plug wire retainer clips to the intake manifold bracket and the heater inlet/outlet hose/pipe bracket.
  24. Connect the left side spark plug wires to the ignition coil.
  25. Connect the left side spark plug wires to the spark plugs.
  26. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.

  27. Object Number: 1608290  Size: SH
  28. Connect the EVAP canister purge solenoid electrical connector (1).
  29. Connect the chassis EVAP line quick connect fitting to the purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service.
  30. Connect the ETC electrical connector (2).

  31. Object Number: 1608869  Size: SH
  32. Connect the MAP sensor electrical connector (1).
  33. Connect the BARO sensor electrical connector.

  34. Object Number: 1608325  Size: SH
  35. Position the hoses/pipes.
  36. Install the heater inlet and outlet hoses/pipes to the engine pipes and the throttle body studs.
  37. Install the heater inlet and outlet hose/pipe clamp nuts to the throttle body studs.
  38. Tighten
    Tighten the nuts to 10 N·m (89 lb in).

  39. Position the heater inlet and outlet hose/pipe clamps at the engine pipes.

  40. Object Number: 1608820  Size: SH
  41. Install the vacuum hose to the intake manifold.

  42. Object Number: 1608801  Size: SH
  43. Install the PCV foul air tube. Refer to Plastic Collar Quick Connect Fitting Service.

  44. Object Number: 1608799  Size: SH
  45. Install the PCV fresh air tube. Refer to Plastic Collar Quick Connect Fitting Service.
  46. Fill the cooling system. Refer to Cooling System Draining and Filling.
  47. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  48. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement.