GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2004 🢒 Grand Am 🢒 Engine 🢒 Engine Controls - 3.4L 🢒 Upper Intake Manifold Replacement

Removal Procedure
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Remove the air cleaner assembly . Refer to Air Cleaner Assembly Replacement in Engine Controls.
  3. Drain cooling system. and to Cooling System Draining and Filling in Engine Cooling.
  4. Remove the exhaust gas recirculation (EGR) pipe, if equipped. Refer to Exhaust Gas Recirculation Pipe Replacement in Engine Controls-3.4L.
  5. Remove the brake vacuum pipe at the plenum.

    6. Object Number: 16290 Size: SH
  6. Disconnect the fuel pressure regulator vacuum hose (1) from the fuel pressure regulator (3) and the PCV valve (2).

    7. Object Number: 258777 Size: SH
  7. Remove the electronic ignition coil and module assembly. Refer to Ignition Control Module Replacement in Engine Controls-3.4L.

    8. Object Number: 73898 Size: SH
  8. Remove evaporative emissions (EVAP) canister purge solenoid.

    9. Object Number: 69065 Size: SH
  9. Disconnect the throttle position (TP) sensor.

    10. Object Number: 12735 Size: SH
  10. Remove throttle cable bracket with cables.

    11. Object Number: 69056 Size: SH
  11. Disconnect the idle air control (IAC) sensor.
  12. Disconnect the Injector harness.

    13. Object Number: 12615 Size: SH
  13. Remove the manifold absolute pressure (MAP) sensor vacuum line (3).
  14. Disconnect the electrical connector.
  15. Remove the MAP sensor bolts (2).
  16. Remove the MAP sensor (1).
  17. Disconnect the coolant hoses from the throttle body.

    18. Object Number: 325936 Size: SH
  18. Remove the upper intake manifold bolts.

    19. Object Number: 96379 Size: SH
  19. Remove the upper intake manifold and gaskets.
  20. Clean the gasket surfaces.

Installation Procedure

    Object Number: 325936 Size: SH
  1. Install the upper intake manifold gaskets on the manifold.

    2. 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.

  2. Apply thread lock GM PN 12345382 to the threads of the bolts.

    3. Install the upper intake manifold bolts.

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


    Object Number: 12615 Size: SH
  3. Install the MAP sensor bolts (2).
  4. Install the MAP sensor vacuum line (3).
  5. Connect the MAP sensor electrical connector.
  6. Connect the vacuum modulator.

    7. Object Number: 16290 Size: SH
  7. Install the vacuum hose (1) to the fuel pressure regulator (3) and the crankcase ventilation valve (2).

    8. Object Number: 69065 Size: SH
  8. Connect the throttle position (TP) sensor.

    9. Object Number: 69056 Size: SH
  9. Connect the IAC.
  10. Connect the injector harness.
  11. Connect the coolant hoses from the throttle body.

    12. Object Number: 73898 Size: SH
  12. Install the EVAP canister purge solenoid.

    13. Object Number: 258777 Size: SH
  13. Install the electronic ignition coil and module assembly. Refer to Ignition Control Module Replacement in Engine Controls-3.4L.
  14. Install the EGR pipe, if equipped. Refer to Exhaust Gas Recirculation Pipe Replacement in Engine Controls.

    15. Object Number: 12735 Size: SH
  15. Install the throttle cables and bracket to the throttle body.
  16. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls.
  17. Install the brake vacuum pipe.
  18. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  19. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  20. Inspect for proper fluid levels.
  21. Inspect for leaks.