GM Service Manual Online
For 1990-2009 cars only

Intake Plenum Switchover Valve Replacement Plenum

Tools Required

J 43914 Universal Clamp Pliers

Removal Procedure


    Object Number: 894285  Size: SH
  1. Disconnect the negative battery cable.
  2. Remove the air cleaner and air inlet hose from the throttle body.

  3. Object Number: 894680  Size: SH
  4. Remove the throttle body electrical connector.

  5. Object Number: 896429  Size: SH
  6. Remove the electrical connector and vacuum hose from the intake plenum switchover valve solenoid.
  7. Remove the vacuum hose from the fuel pressure regulator.

  8. Object Number: 896433  Size: SH
  9. Remove the intake plenum hose clamps using the J 43914 and remove the bolts.
  10. Important: It is only necessary to remove the front intake runner to remove the intake plenum.

  11. Remove the intake plenum.

  12. Object Number: 896435  Size: SH
  13. Remove the plenum mounting bolts and EGR pipe connection.
  14. Lift the plenum and remove the throttle body coolant hoses.

  15. Object Number: 894807  Size: SH
  16. Remove the throttle body nuts.
  17. Remove the throttle body.

Installation Procedure


    Object Number: 896465  Size: SH
  1. Install the rear manifold runner, if required. Route the crankcase hoses under the runner.
  2. Install the heater hose.
  3. Route the crankcase hoses under the runner.
  4. Install the coolant hose.

  5. Object Number: 894807  Size: SH
  6. Install the throttle body gasket to the plenum.
  7. Install the throttle body to the plenum.
  8. Install the throttle body nuts.
  9. Tighten
    Tighten the throttle body nuts to 8 N·m (71 lb in).

  10. Install the intake plenum and intake plenum nuts.
  11. Insert the intake plenum bolts.
  12. Tighten
    Tighten the intake plenum bolts to 8 N·m (71 lb in).

  13. Attach the coolant hoses to the throttle body.
  14. Install the EGR pipe connection.
  15. Tighten
    Tighten the EGR pipe bolts to 25 N·m (18 lb ft).


    Object Number: 896433  Size: SH
  16. Install the front manifold runner and tighten the clamps.
  17. Connect the negative battery cable.
  18. Tighten
    Tighten the battery terminal bolt to 17 N·m (13 lb ft).

  19. Install the intake manifold runner bolts.
  20. Tighten
    Tighten the intake manifold runner bolts to 8 N·m (71 lb in).

Intake Plenum Switchover Valve Replacement Runner - Bank 1

Tools Required

J 43914 Universal Clamp Pliers

Removal Procedure


    Object Number: 894285  Size: SH
  1. Disconnect the negative battery cable.
  2. Remove the intake hose assembly. Refer to Air Cleaner and Intake Hose.

  3. Object Number: 894699  Size: SH
  4. Remove the ECM electrical connectors.
  5. Remove the ECM bolts and ECM.

  6. Object Number: 896429  Size: SH

    Important: Clamps are reusable if not damaged. Do not discard.

  7. Remove the rubber boot hose clamps using the J 43914 .

  8. Object Number: 894808  Size: SH
  9. Disconnect the brake vacuum hose.
  10. Important: Note the proper hose routing.

  11. Disconnect the intake plenum switch-over valve vacuum hose at the switch-over valve.

  12. Object Number: 893560  Size: SH
  13. Remove the intake runner mounting bolts.
  14. Disconnect the intake runner from the rubber boots and remove the intake runner. Note the throttle body vent hose routing under the vacuum reservoir.

Installation Procedure


    Object Number: 896465  Size: SH
  1. Install the intake runner onto the rubber boots.
  2. Route the throttle body vent hose under the vacuum reservoir.
  3. Install the intake runner mounting bolts.
  4. Tighten
    Tighten the intake manifold runner bolts to 8 N·m (71 lb in).


    Object Number: 896429  Size: SH
  5. Route the intake plenum switch-over valve vacuum hose and connect to the switch-over valve.

  6. Object Number: 894808  Size: SH
  7. Connect the brake vacuum line.
  8. Install the rubber boot hose clamps using the J 43914 .

  9. Object Number: 894699  Size: SH
  10. Install the ECM and ECM bolts.
  11. Tighten
    Tighten the engine control module bolts to 8 N·m (71 lb in).


    Object Number: 894285  Size: SH
  12. Install the air cleaner inlet hose assembly. Refer to Air Cleaner and Hose Assembly.
  13. Connect the negative battery cable.
  14. Tighten
    Tighten the battery terminal bolts to 17 N·m (13 lb ft).

Intake Plenum Switchover Valve Replacement Runner - Bank 2

Tools Required

J 43914 Universal Clamp Pliers

Removal Procedure


    Object Number: 894285  Size: SH
  1. Disconnect the negative battery cable.
  2. Remove the air cleaner inlet hose assembly from the throttle body.

  3. Object Number: 893560  Size: SH

    Important: Clamps are reusable if not damaged. Do not discard.

  4. Remove the rubber boot hose clamps using the J 43914 .

  5. Object Number: 896433  Size: SH
  6. Remove the intake runner mounting bolts.
  7. Disconnect the intake runner from the rubber boots and remove the intake runner.

Installation Procedure


    Object Number: 896433  Size: SH
  1. Install the rubber boots on the intake runner.
  2. Install the intake runner mounting bolts.
  3. Tighten
    Tighten the intake manifold runner bolts to 8 N·m (71 lb in).


    Object Number: 893559  Size: SH

    Important: Inspect the hose clamps for damage. Replace if damaged.

  4. Install the rubber boot hose clamps using the J 43914 .

  5. Object Number: 894285  Size: SH
  6. Install the intake hose assembly.
  7. Connect the negative battery cable.
  8. Tighten
    Tighten the battery terminal bolts to 17 N·m (13 lb ft).