Important: The intake manifold, throttle body, fuel rail, and injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.

1. Disconnect the following electrical connectors:

•	Mass airflow (MAF) sensor (1)

•	Intake air temperature (IAT) sensor (2)




2. Loosen the clamp at the air cleaner.
3. Remove the air cleaner bolts.
4. Remove the air cleaner.



5. Loosen the clamp (2) at the throttle body (1).
6. Remove the air cleaner duct (3).



7. Remove the coolant recovery reservoir bolt.
8. Reposition the coolant recovery reservoir to the side.
9. Remove the engine cover. Refer to Engine Cover Replacement in Interior Trim.
10. Relieve the fuel system pressure. Refer to Fuel Pressure Relief in Engine Controls - 8.1L.



11. Remove the oil fill tube bracket bolt and tube.



12. Remove the air conditioning (A/C) compressor bolts.



13. Disconnect the following A/C compressor electrical connectors:

•	A/C compressor (1)

•	A/C high pressure switch (2)

14. Reposition the A/C compressor.



15. Remove the exhaust gas recirculation (EGR) valve pipe bolts (2) from the EGR valve.
16. Reposition the EGR valve pipe.



17. Disconnect the following electrical connectors:

•	Purge valve solenoid (1)

•	Ignition coil harness (2)

•	Engine coolant temperature (ECT) sensor (3)

18. Remove the ECT sensor wire clip from the ignition coil harness.



19. Disconnect the following electrical connectors:

•	Manifold absolute pressure (MAP) sensor (1)

•	EGR valve (2)

20. Disconnect the vacuum hose from the rear of the intake manifold.



21. Disconnect the following electrical connectors:

•	Ignition coil (1)

•	Throttle position sensor (TPS) (3)

•	Electronic throttle control (ETC) (4)

22. Remove the passenger rear, and the drivers front and rear harness clip bolts from the top of the intake manifold.
23. Open the passenger front harness clip. Remove the harness from the clip.
24. Reposition the engine wiring harness.



25. Disconnect the evaporative emission canister tube from the purge solenoid.



26. Disconnect the EVAP canister tube clip from the fuel rail.
27. Disconnect the EVAP canister tube from the canister.
28. Remove the EVAP canister tube.
29. Disconnect the fuel line quick connect fittings. Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service in Engine Controls - 8.1L.



30. Remove the intake manifold bolts.

Important: Do not attempt to loosen the manifold by prying under the gasket surface with any tool.

31. Remove the intake manifold.




Important: The intake manifold gaskets are not reusable.

32. Remove and discard the intake manifold side gaskets.



33. Remove and discard the lower intake manifold end seals.




Important: The splash shield is secured using a snap-in fit. Do not distort the splash shield. The splash shield is reusable.

34. Remove the splash shield.



35. If replacement of the intake manifold is required, remove the throttle body nuts. Remove the throttle body and gasket.



36. If replacement of the intake manifold is required, remove the fuel pressure regulator vacuum hose.



37. If replacement of the intake manifold is required, remove the fuel rail studs and nuts. Remove the fuel rail and injectors.



38. If replacement of the intake manifold is required, remove the purge solenoid bolt and purge solenoid.



39. If replacement of the intake manifold is required, remove the MAP sensor bolt and sensor. Inspect the MAP sensor for damage.



40. If replacement of the intake manifold is required, remove the EGR valve nuts (1). Remove the EGR valve (2) and gasket (3).

Discard the gasket.

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.

1. If replacement of the intake manifold was required, install a NEW EGR valve gasket (3), the EGR valve (2), and EGR valve nuts (1).

Tighten
Tighten the EGR valve nuts to 22 N·m (16 lb ft).





Important: Lubricate the port of the MAP sensor with clean engine oil. Avoid dipping the sensor port directly into the lubricant or using a solid type of lubricant, as they may block the vacuum port signal.

2. If replacement of the intake manifold was required, install the MAP sensor and bolt.

Tighten
Tighten the MAP sensor bolt to 12 N·m (106 lb in).





Important: Apply a very light film of clean engine oil to the purge solenoid seal.

3. If replacement of the intake manifold was required, install the purge solenoid and bolt.

Tighten
Tighten the purge solenoid bolt to 10 N·m (89 lb in).




4. If replacement of the intake manifold was required, install the fuel rail with injectors. Install the fuel rail studs and nuts.

Tighten
Tighten the fuel rail studs and nuts to 12 N·m (106 lb in).




5. If replacement of the intake manifold was required, install the fuel pressure regulator vacuum hose.



6. If replacement of the intake manifold is required, install a NEW throttle body gasket and the throttle body. Install the throttle body nuts.

Tighten
Tighten the throttle body nuts to 10 N·m (89 lb in).




7. Install the intake manifold splash shield.



8. Ensure the splash shield (2) snap fits between the cylinder heads (1).



9. Install NEW intake manifold end seals.



10. Install NEW intake manifold side gaskets.



11. Ensure the intake manifold gasket tabs align with the hole in the head gasket.
12. Ensure the intake manifold gasket tabs align with the slot in the intake manifold end seals.



13. Install the intake manifold.



14. Apply threadlock GM U.S. P/N 12345382, Canada P/N 10953489, or equivalent to a minimum of eight threads of the intake manifold bolts.

Important: 

•	The entire intake manifold tightening sequence must be followed exactly, or an oil leak resulting in engine damage may occur. Ensure the intake manifold is tightened without allowing the intake manifold to shift.

•	The entire intake manifold tightening sequence must be promptly completed due to anaerobic thread adhesive. The final pass of the tightening sequence must be completed before the adhesive starts to cure, or false torque readings and ineffective thread locking may result.

15. Install the intake manifold bolts.
16. Tighten the intake manifold bolts in sequence, using four passes.

Tighten

1. Snug the intake manifold bolts in sequence to 5 N·m (44 lb in) on the first pass.
2. Snug the intake manifold bolts in sequence to 5 N·m (44 lb in) on the second pass. Inspect the intake manifold joints for signs of intake manifold shifting. Correct as required.
3. Tighten the intake manifold bolts in sequence to 10 N·m (89 lb in) on the third pass.
4. Tighten the intake manifold bolts in sequence to 12 N·m (106 lb in) on the final pass.
17. Connect the fuel line quick connect fittings.



18. Install the EVAP canister tube.
19. Connect the EVAP canister tube to the canister.
20. Connect the EVAP canister tube clip to the fuel rail.



21. Connect the EVAP emission canister tube to the purge solenoid.



22. Position the engine wiring harness to the intake manifold.
23. Install the passenger rear, and the drivers front and rear harness clip bolts to the top of the intake manifold.

Tighten
Tighten the engine wiring harness clip bolts to 5 N·m (44 lb in).

24. Install the harness to the passenger front clip. Close the clip.
25. Connect the following electrical connectors:

•	Ignition coil (1)

•

TPS (3)

•

ETC (4)

26. Connect the vacuum hose to the rear of the intake manifold.



27. Connect the following electrical connectors:

•	MAP sensor (1)

•	EGR valve (2)

28. Install the ECT sensor wire clip to the ignition coil harness.



29. Connect the following electrical connectors:

•	Purge valve solenoid (1)

•	Ignition coil harness (2)

•	ECT sensor (3)




30. Position the EGR valve pipe.
31. Install the EGR valve pipe bolts (2) to the EGR valve.

Tighten
Tighten the EGR valve pipe bolts to 25 N·m (19 lb ft).




32. Position the A/C compressor.
33. Connect the following A/C compressor electrical connectors:

•	A/C compressor (1)

•	A/C high pressure switch (2)




34. Install the A/C compressor bolts.

Tighten
Tighten the A/C compressor bolts to 50 N·m (37 lb ft).




35. Install the oil fill tube and bolt.

Tighten
Tighten the oil fill tube bracket bolt to 12 N·m (106 lb in).

36. Install the engine cover. Refer to Engine Cover Replacement in Interior Trim.



37. Position the coolant recovery reservoir.
38. Install the coolant recovery reservoir bolt.

Tighten
Tighten the coolant recovery reservoir bolt to 7 N·m (62 lb in).




39. Install the air cleaner duct (3).
40. Position and tighten the clamp (2) at the throttle body (1).

Tighten
Tighten the air cleaner duct clamp to 4 N·m (35 lb in).




41. Install the air cleaner.
42. Install the air cleaner bolts.

Tighten
Tighten the air cleaner bolts to 10 N·m (89 lb in).

43. Tighten the clamp at the air cleaner.

Tighten
Tighten the air cleaner duct clamp to 4 N·m (35 lb in).




44. Connect the following electrical connectors:

•	MAF sensor (1)

•	IAT sensor (2)