Intake Manifold Tube Replacement LLY, LBZ

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. Remove the front intake manifold tube bolt.
7. Reposition the positive battery cable boot.
8. Remove the positive battery cable nut at the IAH.
9. Remove the positive battery cable from the IAH stud.



10. Remove the engine wiring harness clip bolt (1) at the rear of the intake manifold tube.
11. Remove the 2 rear intake manifold tube bolts (3).
12. Remove the rear intake manifold tube nut (2).



13. Remove the engine wiring harness clip from the intake manifold tube.
14. Remove the engine wiring harness clip bolt (3).
15. Remove the exhaust gas recirculation (EGR) cooler water pipe bracket bolt (5).
16. Remove the intake manifold tube bolts (2, 4) and nut (1).



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. 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. Remove the front intake manifold tube bolts, the front intake manifold tube, and the IAH.

1. If the intake manifold tube was replaced perform the following steps, otherwise proceed to step 5.

Notice: Refer to Fastener Notice in the Preface section.

2. Position the IAH and the front intake manifold tube to the intake manifold tube, install the front intake manifold tube bolts.

Tighten
Tighten the bolts to 20 N·m (15 lb ft).




3. Install the MAP sensor and bracket.
4. Install the MAP sensor bolt.

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




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.

Tighten
Tighten the stud to 25 N·m (18 lb ft).




8. Install the intake manifold tube bolts (2, 4) and nut (1).

Tighten
Tighten the bolt/nut to 25 N·m (18 lb ft).

9. Install the EGR cooler water pipe bracket bolt (5).

Tighten
Tighten the bolt to 15 N·m (11 lb ft).

10. Install the engine wiring harness clip bolt (3).

Tighten
Tighten the bolt to 15 N·m (11 lb ft).

11. Install the engine wiring harness clip to the intake manifold tube.



12. Install the rear intake manifold tube nut (2).

Tighten
Tighten the nut to 25 N·m (18 lb ft).

13. Install the 2 rear intake manifold tube bolts (3).

Tighten
Tighten the bolt to 25 N·m (18 lb ft).

14. Install the engine wiring harness clip bolt (1) at the rear of the intake manifold tube.

Tighten
Tighten the bolt to 15 N·m (11 lb ft).




15. Install the positive battery cable to the IAH stud.
16. Install the positive battery cable nut at the IAH.

Tighten
Tighten the nut to 10 N·m (89 lb ft).

17. Position the positive battery cable boot.
18. Install the front intake manifold tube bolt.

Tighten
Tighten the bolt to 15 N·m (11 lb ft).




19. Connect the engine harness electrical connector to the IAH.
20. Connect the engine harness electrical connector 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 .