Upper Intake Manifold Replacement

UPPER INTAKE MANIFOLD ASSEMBLY










Remove or Disconnect
1. Battery negative cable assembly.
2. Drain coolant.
3. Throttle body air duct.
4. Fuel rail injector wiring harness connectors.
5. Wiring hamess retaining nut and lay harness aside.
6. Accelerator cable bracket bolts/screws, bracket and cables from throttle body assembly.
7. Relieve fuel system pressure.
8. Fuel pipe connectors.
9. Fuel pipe bracket bolts/screws.
10. Fuel pipe hold down plate bolt/screw (167).
11. Fuel pipe assembly and reposition.
12. Coolant hoses from throttle body assembly.
13. Fuel rail stud (169).
14. Fuel pressure regulator vacuum hose.
15. Wiring harness electrical connectors from the following:
- Idle air control
- Throttle position sensor
- Manifold absolute pressure sensor
- Evaporative emissions canister purge solenoid valve

16. Blow dirt out of injector bores with compressed air.
17. Fuel rail assembly (166).
18. Vacuum harness assembly.
19. Exhaust gas recirculation (EGR) flexible pipe bolts/ screws and reposition EGR flexible pipe assembly and gasket at upper intake manifold assembly (155).
20. Upper intake manifold bolts/screws (156).
21. Upper intake manifold assembly (155) and gasket (154)


Clean
- Upper intake manifold bolts/screws (156).
- Upper intake manifold sealing surfaces.


Install or Connect
1. Upper intake manifold gasket (154) and manifold assembly (155).
2. Upper intake manifold bolts/screws (156).
- Tighten Upper intake manifold bolts/screws (156) to 25 N.m (18 lb. ft.).

3. EGR flexible pipe gasket, pipe assembly and bolts/ screws at upper intake manifold assembly (155).
A. Apply teflon sealant GM P/N 1052080 to threads of bolts/screws.
B. Gasket must be installed with text "tube side" facing the tube.
Tighten EGR flexible pipe bolts/screws to 26 N.m (19 lb. ft.).

4. Vacuum harness assembly.

Important: Do not press on the regulator cover or piedmont valve when installing fuel rail assembly.

5. Fuel rail assembly (166).
A. Lightly lubricate fuel injector 0-rings using clean engine oil.
B. Install injectors of fuel rail assembly (166) into bores of manifold.
C. Carefully press on fuel rail assembly (166) with palms of both hands until injectors are fully seated.

6. Fuel rail stud (169).
- Tighten Fuel rail stud (169) to 25 N.m (19 lb. ft.).

7. Wiring harness electrical connectors to the following:
- Idle air control
- Throttle position sensor
- Manifold absolute pressure sensor
- Evaporative emissions canister purge solenoid valve

8. Fuel pressure regulator vacuum hose.
9. Fuel rail wiring harness retaining nut.
10. Fuel pipe assembly to fuel rail assembly (166).
- Slide fuel line hold down plate over fuel pipe assembly.

11. Fuel pipe hold down plate bolt/screw (167).
- Apply teflon sealant GM P/N 1052080 to threads of bolt/screw (167).
- Tighten Fuel pipe hold down plate bolt/screw (167) to 25 N.m (18 lb. ft.)

12. Fuel pipe bracket bolts/screws.
13. Accelerator cable bracket, bolts/screws and cables.
- Tighten Accelerator cable bracket bolts/screws to 10 N.m (90 lb. in.).
- Tighten Fuel pipe bracket-to-front brace bolt/screw to 8 N.m (71 lb. in.)
- Tighten Fuel pipe bracket-to-intake manifold assembly bolt/screw to 10 N.m (89 lb. ft.).

14. Fuel pipe connectors.
15. Fuel rail injector wiring harness connectors.
16. Coolant hoses to throttle body assembly.
17. Throttle body air duct.
18. Battery negative cable assembly.
19. Refill with coolant.