Intake Manifold Replacement - Lower

Intake Manifold Replacement - Lower
^ Tools Required
- J23600-B Torque Angle Meter

Removal Procedure





1. Remove the upper intake manifold. - Upper.
2. Remove the valve rocker covers.
3. Remove the fuel rail with injectors and position aside.
4. Disconnect ECT.





5. Remove the power steering mounting bolts. Position the pump aside.





6. Remove the inlet cooling pipe from the coolant outlet housing.
7. Remove the heater by-pass at the coolant pump and the cylinder head.
8. Remove the radiator hose from thermostat housing.
9. Remove the water outlet housing.

Important: Retain the washers in the same orientation on the center bolts.





10. Remove the lower intake manifold bolts.
11. Remove the lower intake manifold.





12. Loosen the rocker arms.

Important: Keep the pushrods in order. The pushrods must be installed in the original position.





13. Remove the pushrods.





14. Remove the intake gasket.
15. Inspect the flatness of the inlet flanges.
16. Clean the following items:
^ Gasket material from the mating surfaces
^ Excess RTV sealant from the front and the rear ridges of the cylinder
^ The block
^ Sealing surfaces
Use degreaser in order to clean the sealing surfaces.

17. If replacing intake remove the following components:
^ ECT
^ Thermostat housing
^ Thermostat

Installation Procedure





1. If removed intake install the following components:
^ ECT
^ Thermostat housing
^ Thermostat

2. Place a 2-3 mm bead of GM sealer P/N 12345739, or the equivalent on each ridge where the front and the rear of the intake manifold contact the block.





3. Install the intake manifold gasket.





4. Install the pushrods and rocker arms.





5. Install the lower intake manifold.

Notice: Failure to tighten vertical bolts before the diagonal bolts may cause an oil leak.

6. Apply sealant GM P/N 12345382 to the threads of the bolts.
Install the lower intake manifold bolts.

Notice: Refer to Fastener Notice in Service Precautions.





7. Install NEW lower intake manifold bolts.

The torque specification is a 2-step process; tighten the vertical lower intake manifold bolts (the four middle ones) to 7 Nm (62 lb in). Tighten the diagonal lower intake manifold bolts (two on each end) to 7 Nm (62 lb in).Tighten the vertical lower intake manifold bolts (the four middle ones) to 13 Nm (115 lb in). Tighten the diagonal lower intake manifold bolts (two on each end) to 25 Nm (18 lb ft).

9. Install the valve rocker covers.
10. Install the radiator hose to the thermostat housing.





11. Install the heater inlet pipe to the thermostat housing.





12. Install the fuel rail with injectors.
13. Install power steering pump.
14. Connect ECT electrical.





15. Install the upper intake manifold. - Upper.