Upper Intake Manifold Replacement

Removal Procedure





1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure.
2. Carefully remove the throttle body air inlet duct.
3. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
4. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement.
5. Disconnect the right spark plug wires. Refer to Spark Plug Wire Harness Replacement in Powertrain Management.
6. Disconnect the evaporative emissions canister purge solenoid valve wiring harness connector.
7. Relieve the fuel pressure. Refer to Fuel Pressure Relief Procedure.
8. Remove the fuel rail. Refer to Fuel Rail Assembly Replacement.
9. Remove the brake booster hose from the vacuum source manifold in the upper intake manifold. Refer to Vacuum Brake Booster Hose Replacement in Brakes and Traction Control.
10. Remove the EGR valve wiring harness heat shield nut and bolt and the EGR shield from the upper intake manifold.





11. Remove the throttle body support bracket bolts and the support bracket.





12. Disconnect the MAP sensor electrical connector. Refer to MAP Sensor Replacement (VIN 1) or MAP Sensor Replacement (VIN K).
13. Remove the upper intake manifold bolts and stud.
14. Clean the upper intake manifold bolt threads.
15. Remove the upper intake manifold.





16. Remove the upper-to-lower intake manifold carrier gasket from the upper intake manifold.
17. If the upper intake manifold is being replaced, remove the throttle body. Refer to Throttle Body Assembly Replacement (VIN K) or Throttle Body Assembly Replacement (VIN 1).





18. If the upper intake manifold is being replaced, remove the vacuum source manifold.

Installation Procedure





1. If the upper intake manifold is being replaced, install the vacuum source manifold.
2. If the upper intake manifold is being replaced, install the throttle body. Refer to Throttle Body Assembly Replacement (VIN K) or Throttle Body Assembly Replacement (VIN 1).





3. Install the upper-to-lower intake manifold carrier gasket to the upper intake manifold.





4. Carefully place the upper intake manifold onto the lower intake manifold. Ensure that the alignment pins in the upper intake manifold align with the holes in the lower intake manifold.
5. Install the upper intake manifold.
6. Apply thread lock compound GM P/N 12345382 or equivalent, to the bolt threads before assembly.

Notice: Refer to Fastener Notice in Service Precautions.





7. Install the upper intake manifold bolts (1-10).
Tighten the upper intake manifold bolts in sequence to 10 Nm (89 inch lbs.).
8. Connect the MAP sensor electrical connector. Refer to MAP Sensor Replacement (VIN 1) or MAP Sensor Replacement (VIN K).





9. Install the throttle body support bracket.
10. Install the throttle body support bracket bolts.
Tighten the throttle body support bracket bolts to 10 Nm (89 inch lbs.).





11. Install the EGR valve wiring harness heat shield and the EGR shield nut and bolt to the upper intake manifold.
Tighten the EGR valve wiring harness heat shield nut and bolt to 10 Nm (89 inch lbs.).
12. Install the brake booster hose to the vacuum source manifold in the upper intake manifold. Refer to Vacuum Brake Booster Hose Replacement in Brakes and Traction Control.
13. Install the fuel rail. Refer to Fuel Rail Assembly Replacement.
14. Connect the evaporative emissions canister purge solenoid valve wiring harness connector.
15. Install the right spark plug wires. Refer to Spark Plug Wire Harness Replacement in Powertrain Management.
16. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement.
17. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
18. Carefully install the throttle body air inlet duct.
19. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure.
20. Inspect for the proper fluid levels.
21. Inspect for fluid or vacuum leaks.