Intake Manifold

REMOVE OR DISCONNECT
1. Negative battery cable
2. Cables at throttle body
3. Brake vacuum pipe at plenum
4. Cable bracket at plenum
5. Air intake duct at throttle body
6. Throttle body at plenum
7. EGR valve at plenum
8. Plug harness at plenum
9. Plenum bolts
10. Plenum
11. Fuel lines at fuel rail

CAUTION Relieve fuel pressure

12. Serpentine belt cover
13. Serpentine belt
14. Generator (support aside)
15. Power steering lines at generator bracket
16. Power steering mounting bolts (support pump aside)
17. Wires at fuel injectors
18. Fuel rail.
19. Plug wires at intake
20. Drain cooling system
21. Heater pipe at water pump and cylinder head
22. Front Valve cover
23. PCV hose
24. Generator brace
25. Generator bracket
26. Rear Valve cover
27. Upper radiator hose
28. Any necessary wiring
29. Coolant sensor
30. Fuel lines at bracket
31. Throttle body heater hose
32. Heater pipe at intake
33. Intake manifold bolts

Note Retain Belleville washers in same orientation on 4 center bolts.

34. Loosen rocker arms
35. Push rods
^ Intake and exhaust pushrods are different lengths. Intake pushrods are marked orange; exhaust pushrods are marked blue.
36. Intake gasket

INSPECT
^ Flatness of inlet flanges

CLEAN
^ Gasket material from mating surfaces
^ Excess RTV sealant from front and rear ridges of cylinder
^ Block
^ Sealing surfaces with degreaser

INSTALL OR CONNECT
1. Place a bead of GM RTV sealer (pin 1052917) or equivalent on each ridge where the front and rear of the intake manifold contact the block
2. Intake manifold gasket
3. Pushrods
^ Intake pushrods are marked orange
^ Exhaust pushrods are marked blue
^ Make sure pushrods seat in lifter
4. Rocker arm nuts
Tighten
^ Rocker arm nuts to 24 Nm (18 ft. lb.)
5. Intake manifold
6. Intake manifold bolts
Tighten
^ bolts to 33 Nm (23 ft. lb.)
7. Heater pipe to manifold
8. Throttle body heater hose
9. Coolant sensor
10. Any necessary wiring
11. Upper radiator hose
12. Rear Valve cover
Tighten
^ Valve cover bolts to 10 Nm (89 in. lb.)
13. Generator bracket
14. Generator brace
15. PCV hose
16. Front Valve cover
Tighten
^ Valve cover bolts to 10 Nm (89 in. lb.)
17. Heater pipe at water pump and cylinder head
18. Plug wires
19. Fuel rail
20. Wires at injectors
21. Power steering pump
22. Power steering line at generator bracket
23. Generator
24. Fuel lines to fuel rail
25. Fuel lines at bracket
26. Serpentine belt
27. Serpentine belt cover
28. Plenum
29. Plenum bolts
Tighten
^ Plenum bolts to 21 Nm (16 ft. lb.)
30. Plug harness
31. EGR valve
32. Throttle body
33. Air intake duct
34. Cable bracket
35. Brake vacuum pipe
36. Cables to throttle body
37. Fill cooling system.
38. Negative battery cable

INSPECT
^ Proper fluid levels
^ Leaks
^ Completion of repair