Upper Intake Manifold Replacement
Intake Manifold Replacement - UpperRemoval Procedure
Important: You do not have to remove the upper intake manifold in order to remove the lower intake manifold.
1. Remove the engine cover.
2. Remove the air cleaner outlet duct from the throttle body.
3. Disconnect the accelerator control cable from the throttle shaft and the accelerator control cable bracket.
4. Disconnect the cruise control cable, if equipped from the throttle shaft and the accelerator control cable bracket.
5. Remove the PCV valve hose assembly from the intake manifold and the valve rocker arm cover.
6. Remove the nut holding the A/C hose bracket, if equipped to the intake manifold stud.
7. Remove the A/C hose bracket from the stud.
8. Remove the nut holding the engine wiring harness bracket to the intake manifold stud.
9. Remove the engine wiring harness bracket from the stud.
10. Disconnect the following electrical connectors:
^ The A/C compressor clutch, if equipped (1)
^ The A/C high pressure cutoff switch, if equipped (5)
^ The throttle position (TP) sensor (2)
^ The idle air control (IAC) motor (3)
^ The fuel meter body assembly connector (4)
11. Disconnect the following electrical connectors:
^ The manifold absolute pressure (MAP) sensor (4)
^ The EVAP canister purge solenoid valve (1)
12. Remove the engine wiring harness bracket from the stud at the EVAP canister purge solenoid valve.
13. Move and secure the engine wiring harness out of the way.
14. Remove the EVAP canister purge valve to Evaporative Emission (EVAP) Canister Purge Valve Replacement.
15. Disconnect the vacuum hose from the intake manifold.
16. Remove the bolt holding the transmission fluid filler tube to the accelerator control cable bracket.
17. Remove the accelerator control cable bracket from the throttle body and the intake manifold.
18. Remove the fuel lines from the fuel meter body assembly.
19. Remove the studs for the upper intake manifold.
20. Remove the upper intake manifold.
21. Remove the upper intake manifold gasket from the groove.
22. Discard the gasket.
23. Remove the seal from the fuel meter body assembly.
24. Discard the seal.
Important: Do not immerse the assembled upper intake manifold in cleaning solvent.
25. Clean all sealing surfaces and the inside of the upper intake manifold with a shop towel and cleaning solvent.
26. Inspect the upper intake manifold for the following:
^ Cracks or other damage to the exterior
^ Cracking or damage to the gasket grooves
^ Loose or damaged bolt hole thread inserts
27. If replacing the upper intake manifold, turn and remove the PCV valve cover from the upper intake manifold.
28. Remove and discard the seal.
29. Remove the throttle body if replacing the upper intake manifold.
30. Remove the MAP sensor if replacing the upper intake manifold.
Installation Procedure
1. Install the throttle body, if removed.
2. Install the MAP sensor, if removed.
3. Install the PCV valve cover, if removed, using the following procedure:
3.1. Install a NEW seal (O-ring) on the PCV valve cover.
3.2. Lubricate the seal with clean engine oil.
3.3. Install the PCV valve cover in the upper intake manifold.
3.4. Turn and lock the PCV valve cover in position.
4. Install a NEW seal on the fuel meter body assembly.
5. Lubricate the seal with clean engine oil.
6. Install a NEW upper intake manifold to lower intake manifold gasket in the groove of the upper intake manifold.
7. Install the upper intake manifold onto the lower intake manifold.
8. If reusing the fasteners, apply threadlock GM P/N 12345382 or equivalent to the threads of the upper intake manifold attaching bolts.
Notice: Refer to Fastener Notice in Service Precautions.
9. Install the upper intake manifold attaching studs.
9.1. Tighten the upper intake manifold attaching studs on the first pass to 5 Nm (44 inch lbs.).
9.2. Tighten the upper intake manifold attaching studs on the final pass to 9 Nm (80 inch lbs.).
10. Install the fuel lines to the fuel meter body assembly.
11. Install the EVAP canister purge valve.
12. Install the accelerator control cable bracket, studs, and nuts to the intake manifold and the throttle body.
^ Tighten the accelerator control cable bracket nuts and studs to 12 Nm (106 inch lbs.).
13. Connect the vacuum hose to the intake manifold.
14. Install the transmission fluid fill tube and bolt to the accelerator control cable bracket.
^ Tighten the transmission fluid fill tube bolt 6 Nm (53 inch lbs.).
15. Position the engine wiring harness.
16. Connect the following electrical connectors:
^ The A/C compressor clutch, if equipped (1)
^ The A/C high pressure cutoff switch, if equipped (5)
^ The throttle position (TP) sensor (2)
^ The idle air control (IAC) motor (3)
^ The fuel meter body assembly connector (4)
17. Connect the following electrical connectors:
^ The manifold absolute pressure (MAP) sensor (4)
^ The EVAP canister purge solenoid valve (1)
18. Install the engine wiring harness bracket and nut to the intake manifold stud.
^ Tighten the engine wiring harness bracket nut to 12 Nm (106 inch lbs.).
19. Install the A/C hose bracket and nut, if equipped to the intake manifold stud.
^ Tighten the A/C hose bracket nut to 5 Nm (44 inch lbs.).
20. Install the engine wiring harness bracket and the nut onto the stud at the EVAP canister purge solenoid valve.
^ Tighten the engine wiring harness bracket nut to 8 Nm (71 inch lbs.).
21. Connect the PCV valve hose assembly to the intake manifold and the valve rocker arm cover.
22. Install the cruise control cable, if equipped to the throttle shaft and the accelerator control cable bracket.
23. Install the accelerator control cable to the throttle shaft and the accelerator control cable bracket.
24. Install the air cleaner outlet duct to the throttle body assembly.
25. Install the engine cover.