Intake Manifold: Service and Repair

Intake Manifold Replacement
Removal Procedure





1. Important: The intake manifold, throttle body, fuel injection rail, and injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.

Remove the engine sight covers.
2. Remove the air intake duct.
3. Remove the front suspension support brace.
4. Disconnect the electrical connector (1) for the fuel injectors.
5. Disconnect the electrical connectors (3) from the throttle body.
6. Disconnect the fuel feed for the fuel injectors.





7. Remove the vacuum hose from the brake booster.
8. Disconnect the electrical connector from the manifold absolute pressure (MAP) sensor.





9. Remove the MAP sensor (714).
10. Remove the grommet (715) from the sensor, as required.





11. Remove the evaporative emission (EVAP) clip (740), bolt (742), bracket (741), valve (730), and tubes (729, 735).





12. Remove the intake manifold bolts (512) and fuel rail stop bracket (712).
13. Remove the intake manifold (500).





14. Remove the intake manifold gaskets (514).
15. Discard the intake manifold gaskets.

Installation Procedure





1. Important: DO NOT reuse the intake manifold gaskets. Install NEW intake manifold gaskets.

Important: The intake manifold, throttle body, fuel injection rail and fuel injectors may be removed as an assembly. If not servicing the individual components, install the intake manifold as a complete assembly.

Install NEW intake manifold-to-cylinder head gaskets (514).





2. Install the intake manifold (500).
3. Apply a 5 mm (0.20 inch) band of threadlocker GM P/N 12345382 (Canadian P/N 10953489) to the threads of the intake manifold bolts (512).
4. Install the intake manifold bolts (512) and fuel rail stop bracket (712).





5. Notice: Refer to Fastener Notice in Service Precautions.

Tighten the intake manifold bolts.
1. Tighten the intake manifold bolts at first pass in sequence to 5 Nm (44 inch lbs.).
2. Tighten the intake manifold bolts at final pass in sequence to 10 Nm (89 inch lbs.).





6. Lubricate the MAP sensor grommet (715) with clean engine oil.
7. Install the MAP sensor (714) and grommet (715).





8. Notice: Refer to Fastener Notice.

Install the EVAP valve (730), bracket (741), and bolt (742).
Tighten the bolt to 50 Nm (37 ft. lbs.).
9. Install the EVAP tubes (729, 735).
10. Install the fuel rail.
11. Reconnect the electrical connector for the MAP sensor.





12. Install the vacuum hose for the brake booster.





13. Reconnect the electrical connectors (3) to the throttle body.
14. Reconnect the electrical connector (1) for the fuel injectors.
15. Install the front suspension support brace.
16. Install the air intake duct.
17. Install the engine sight covers.