Intake Manifold Replacement - Upper

Intake Manifold Replacement - Upper
Removal Procedure





1. Disconnect the negative battery cable.
2. Remove the intake manifold cover.
3. Drain the cooling system. Refer to Draining and Filling Cooling System.
4. Remove the positive crankcase ventilation (PCV) fresh air tube.





5. Remove the PCV foul air tube.





6. Reposition the brake booster vacuum hose clamp at the intake manifold.
7. Remove the vacuum hose from the intake manifold.





8. Reposition the radiator surge tank inlet hose clamp.
9. remove the radiator surge tank inlet hose from the inlet pipe.





10. Remove the radiator surge tank inlet pipe bolts.
11. Remove the radiator surge tank inlet pipe.





12. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (1).





13. Disconnect the evaporative emission (EVAP) canister purge solenoid electrical connector (1).
14. Disconnect the electronic throttle control (ETC) electrical connector (2).





15. Disconnect the inlet manifold valve electrical connector (1).





16. Remove the air cleaner outlet duct.
17. Disconnect the left side spark plug wires from the spark plugs.
18. Disconnect the left side spark plug wires from the ignition control module.
19. Disengage the spark plug wire retainer clips from the intake manifold bracket and the heater inlet/outlet pipe.
20. Remove the left side spark plug wires.





21. Remove the heater inlet and outlet pipe nuts from the throttle body studs.
22. Remove the inlet and outlet pipe from the studs.





23. Remove the upper intake manifold bolts (1, 2) and stud (3).
24. Separate and remove the upper intake manifold from the lower intake manifold.





25. Remove the upper to lower intake manifold gaskets.





26. Remove the inlet manifold tuning valve bolts and valve.
27. Remove the EVAP canister purge solenoid valve bolt and valve.
28. Remove the MAP sensor bolt, bracket and sensor.
29. Remove the throttle body bolts/studs and throttle body.
30. Clean the upper intake to lower intake gasket mating surfaces.





31. Inspect the intake manifold tuning valve seal for damage. The tuning valve blade attachment to the motor should be tight, with no looseness or slack present, Replace as necessary.
32. Apply lubricant GM P/N 01050344 (Canadian P/N 993037) or equivalent to the nose of the valve blade (1).

Installation Procedure





1. Notice: Refer to Fastener Notice.

Install the inlet manifold tuning valve, and bolts.
Tighten the bolts to 10 Nm (89 inch lbs.).
2. Inspect the EVAP canister purge solenoid valve seal for damage, replace as necessary.
3. Install the EVAP canister purge solenoid valve and bolt.
Tighten the bolts to 16 Nm (12 ft. lbs.).
4. Inspect the MAP sensor seal for damage, replace as necessary.
5. Install the MAP sensor, bracket, and bolt.
Tighten the bolt to 10 Nm (89 inch lbs.).
6. Inspect the throttle body seal for damage, replace as necessary.
7. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the throttle body bolts/studs threads.
8. Install the throttle body and bolts/studs.
Tighten the bolts/studs to 10 Nm (89 inch lbs.).





9. Install the NEW upper to lower intake manifold gaskets.





10. Set the upper intake manifold onto the lower intake manifold.
11. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the upper intake manifold bolts/stud threads.
12. Install the upper intake manifold bolts (1, 2) and stud (3).
Tighten the bolts and stud to 25 Nm (18 ft. lbs.).





13. Install the inlet and outlet pipe to the studs.
14. Install the heater inlet and outlet pipe nuts to the throttle body studs.
Tighten the nuts to 10 Nm (89 inch lbs.).





15. Install the left side spark plug wires.
16. Connect the left side spark plug wires to the spark plugs.
17. Connect the left side spark plug wires to the ignition control module.
18. Engage the spark plug wire retainer clips to the intake manifold bracket and the heater inlet/outlet pipe.
19. Install the air cleaner outlet duct.





20. Connect the inlet manifold valve electrical connector (1).





21. Connect the EVAP canister purge solenoid electrical connector (1).
22. Connect the ETC electrical connector (2).





23. Connect the MAP sensor electrical connector (1).





24. Install the radiator surge tank inlet pipe.
25. Install the radiator surge tank inlet pipe bolts.
Tighten the bolts to 10 Nm (89 inch lbs.).





26. Install the radiator surge tank inlet hose to the inlet pipe.
27. Position the radiator surge tank inlet hose clamp.





28. Install the brake booster vacuum hose to the intake manifold.
29. Position the vacuum hose clamp at the intake manifold.





30. Install the PCV foul air tube.





31. Install the PCV fresh air tube.
32. Fill the cooling system. Refer to Draining and Filling Cooling System.
33. Install the intake manifold cover.
34. Connect the negative battery cable.