GM Service Manual Online
For 1990-2009 cars only

Intake Manifold Replacement LAT

Removal Procedure


    Object Number: 1810743  Size: SH
  1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.
  2. Remove the radiator inlet hose. Refer to Radiator Inlet Hose Replacement.
  3. Disconnect the engine wiring harness electrical connector (1) from the throttle actuator control (TAC).
  4. Disconnect the engine wiring harness electrical connector (2) from the generator starter.
  5. Disconnect the engine wiring harness electrical connector (4) from the generator starter.
  6. Remove the fuel injector wiring harness electrical connector retainer (6) from the generator starter.
  7. Disconnect the fuel injector wiring harness electrical connector (7) from the engine wiring harness electrical connector (8).
  8. Remove the engine wiring harness clips (5) from the intake manifold.

  9. Object Number: 1810786  Size: SH
  10. Reposition the vacuum brake booster hose clamp (1) at the intake manifold.
  11. Remove the vacuum brake booster hose (2) from the intake manifold.

  12. Object Number: 1810824  Size: SH
  13. Remove the throttle body bolts.
  14. Note: The throttle body seal is reusable, only replace the seal if damaged.

  15. Remove the throttle body and seal.
  16. Remove and inspect the throttle body seal.
  17. Disconnect the engine wiring harness electrical connector from the manifold absolute pressure (MAP) sensor.

  18. Object Number: 1623766  Size: SH
  19. Disconnect the evaporative emission (EVAP) canister purge tube from the intake manifold and the EVAP solenoid. Refer to Plastic Collar Quick Connect Fitting Service.
  20. Remove the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement.
  21. Remove the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement.

  22. Object Number: 1810869  Size: SH
  23. Remove the 3-phase voltage cable bracket bolt at the tie bar.

  24. Object Number: 1810870  Size: SH
  25. Remove the generator starter bolts.
  26. Reposition and secure the generator starter out of the way.

  27. Object Number: 1623769  Size: SH
  28. Remove the intake manifold lower bolts.

  29. Object Number: 1656110  Size: SH
  30. Remove the intake manifold upper bolt and nuts.
  31. Remove the intake manifold.
  32. Note: The intake manifold gasket is reusable, only replace the gasket if damage has occurred.

  33. Remove and inspect the intake manifold gasket.

Installation Procedure


    Object Number: 1656110  Size: SH
  1. Install a NEW intake manifold gasket if necessary, otherwise install the old gasket.
  2. Install the intake manifold.
  3. Install the intake manifold upper bolt and nuts.
  4. Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 1623769  Size: SH
  5. Install the intake manifold lower bolts and tighten to 10 N·m (89 lb in).

  6. Object Number: 1810870  Size: SH
  7. Position the starter/generator to the bracket.
  8. Install the starter/generator bolts until snug.
  9. Tighten the starter generator bolts in the following sequence:
  10. 7.1. Front
    7.2. Bottom

    Tighten the bolts to 58 N·m (43 lb ft).


    Object Number: 1810869  Size: SH
  11. Install the 3-phase voltage cable bracket to the tie bar.
  12. Install the 3-phase voltage cable bracket bolt at the tie bar and tighten to 10 N·m (89 lb in).

  13. Object Number: 1623766  Size: SH
  14. Install the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement.
  15. Install the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement.
  16. Connect the EVAP canister purge tube to the intake manifold and the EVAP solenoid. Refer to Plastic Collar Quick Connect Fitting Service.

  17. Object Number: 1810824  Size: SH
  18. Connect the engine wiring harness electrical connector to the MAP sensor.
  19. Install a NEW throttle body seal if necessary, otherwise install the old seal.
  20. Position the throttle body.
  21. Install the throttle body bolts and tighten to 10 N·m (89 lb in).

  22. Object Number: 1810786  Size: SH
  23. Install the vacuum brake booster hose (2) to the intake manifold.
  24. Position the vacuum brake booster hose clamp (1) at the intake manifold.

  25. Object Number: 1810743  Size: SH
  26. Install the engine wiring harness clips (5) to the intake manifold.
  27. Connect the fuel injector wiring harness electrical connector (7) to the engine wiring harness electrical connector (8).
  28. Install the fuel injector wiring harness electrical connector retainer (6) to the generator starter.
  29. Connect the engine wiring harness electrical connector (4) to the generator starter.
  30. Connect the engine wiring harness electrical connector (2) to the generator starter.
  31. Connect the engine wiring harness electrical connector (1) to the TAC.
  32. Install the radiator inlet hose. Refer to Radiator Inlet Hose Replacement.
  33. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.

Intake Manifold Replacement LE5

Removal Procedure


    Object Number: 1647528  Size: SH
  1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement.
  2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.
  3. Disconnect the engine harness electrical connector (1) from the throttle actuator control (TAC).
  4. Disconnect the engine harness electrical connector (2) from the fuel injector harness.
  5. Disconnect the engine harness electrical connector from the manifold absolute pressure (MAP) sensor.

  6. Object Number: 1656100  Size: SH
  7. Disconnect the engine harness clips (1 and 3) from the intake manifold.
  8. Disconnect the engine harness clip (2) from the oil level indicator tube.
  9. Disconnect the fuel injector electrical connector clip from the intake manifold.

  10. Object Number: 1656109  Size: SH
  11. Reposition the vacuum brake booster hose clamp (1) at the intake manifold.
  12. Remove the vacuum brake booster hose from the intake manifold.

  13. Object Number: 1628032  Size: SH
  14. Remove the throttle body bolts.
  15. Note: The throttle body seal is reusable, only replace the seal if damaged.

  16. Remove the throttle body and seal.
  17. Remove and inspect the throttle body seal.

  18. Object Number: 1623766  Size: SH
  19. Disconnect the evaporative emission (EVAP) canister purge tube from the intake manifold and the EVAP solenoid. Refer to Plastic Collar Quick Connect Fitting Service.
  20. Remove the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement.
  21. Remove the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement.

  22. Object Number: 1623769  Size: SH
  23. Remove the intake manifold lower bolts.

  24. Object Number: 1656110  Size: SH
  25. Remove the intake manifold upper bolt and nuts.
  26. Remove the intake manifold.
  27. Note: The intake manifold gasket is reusable, only replace the gasket if damage has occurred.

  28. Remove and inspect the intake manifold gasket.

Installation Procedure


    Object Number: 1656110  Size: SH
  1. Install a NEW intake manifold gasket if necessary, otherwise install the old gasket.
  2. Install the intake manifold.
  3. Install the intake manifold upper bolt and nuts.
  4. Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 1623769  Size: SH
  5. Install the intake manifold lower bolts and tighten to 10 N·m (89 lb in).

  6. Object Number: 1623766  Size: SH
  7. Install the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement.
  8. Install the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement.
  9. Connect the EVAP canister purge tube to the intake manifold and the EVAP solenoid. Refer to Plastic Collar Quick Connect Fitting Service.

  10. Object Number: 1628032  Size: SH
  11. Install a NEW throttle body seal if necessary, otherwise install the old seal.
  12. Position the throttle body.
  13. Install the throttle body bolts and tighten to 10 N·m (89 lb in).

  14. Object Number: 1656109  Size: SH
  15. Install the vacuum brake booster hose to the intake manifold.
  16. Position the vacuum brake booster hose clamp (2) at the intake manifold.

  17. Object Number: 1656100  Size: SH
  18. Connect the engine harness clips  (1 and 3) to the intake manifold.
  19. Connect the engine harness clip (2) to the oil level indicator tube.
  20. Connect the fuel injector electrical connector clip to the intake manifold.

  21. Object Number: 1647528  Size: SH
  22. Connect the engine harness electrical connector (2) to the fuel injector harness.
  23. Connect the engine harness electrical connector to the MAP sensor.
  24. Connect the engine harness electrical connector (1) to the TAC.
  25. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.
  26. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement.