Intake Manifold: Service and Repair

Intake Manifold Replacement

Removal Procedure





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

1. Disconnect the negative battery cable from the battery.
2. Drain the cooling system.
3. Remove the front suspension support brace.
4. Remove the fuel rail covers.
5. Disconnect the air intake sensor connector (2) from the air intake sensor.
6. Loosen the hose clamps (1, 3) securing the intake duct.
7. Remove the intake duct from the vehicle.





8. Depressurize the fuel rail.
9. Disconnect the fuel line (4) from the fuel rail.
10. Disconnect the purge line (1) from the purge valve.





11. Disconnect the connector from the intake air control (IAC) motor (1).
12. Disconnect the connector from the throttle position (TP) sensor (2) at the throttle body.





13. Open the retainer clip at the intake manifold and remove the cable (3) from the clip.





14. Lift the throttle cable (2) up at the throttle body mounting bracket, then remove the cable from the throttle body cam lever (1)
15. Set the throttle cable aside.





16. Disconnect the fuel injector connectors (3) from all the fuel injectors.
17. Remove the locks (1) from the right and left side ignition coil main connectors and disconnect the connectors (2).
18. Disconnect the evaporative emission (EVAP) canister purge solenoid valve electrical connector (5).
19. Remove the harness securing clips (4) from the fuel rail brackets and set the harnesses to one side.





20. Disconnect the manifold absolute pressure (MAP) sensor connector.
21. Disconnect the knock sensor connector.
22. Disconnect the oil pressure sensor connector.
23. Remove the fresh air hose from the rocker cover and the throttle body.
24. Remove the foul air hose from the throttle body and restricting orifice external connector.





25. Remove the engine coolant vent hose from the throttle body and vent pipe.
26. Remove the coolant vent outlet hose from he throttle body and left-hand radiator tank.





27. Remove the EVAP canister purge tube from the following:
^ Throttle body
^ EVAP canister purge solenoid valve





28. Remove the EVAP canister purge solenoid valve and bracket from the intake manifold.





29. Remove the intake manifold bolts (1) and fuel rail stop bracket (2).





30. Remove the intake manifold from the engine.





31. Remove the intake manifold-to-cylinder head gaskets (1).
32. Discard the gaskets.
33. Clean and inspect the intake manifold.

Installation Procedure





1. Install NEW intake manifold-to-cylinder head gaskets (1).





2. install the intake manifold to the engine.





3. Apply threadlock GM P/N 12345382, (Canadian P/N 10953489), or equivalent to the threads of the intake manifold bolts (1).

Caution: The fuel rail stop bracket must be installed onto the engine assembly. The stop bracket serves as a protective shield for the fuel rail in the event of a vehicle frontal crash. If the fuel rail stop bracket is not installed and the vehicle is involved in a frontal crash, fuel could be sprayed possibly causing a fire and personal injury from burns.

4. Install the fuel rail stop bracket (2).





Notice: Refer to Fastener Notice in Service Precautions.

5. Install the intake manifold bolts.
5.1. Tighten the intake manifold bolts a first pass in sequence to 5 Nm (44 inch lbs.).
5.2. Tighten the intake manifold bolts a final pass in sequence to 10 Nm (89 inch lbs.).





6. Install the EVAP canister purge solenoid valve and bracket to the intake manifold.





7. Install the EVAP canister purge tube to the following:
^ Throttle body
^ EVAP canister purge solenoid valve





8. Install the engine coolant vent hose to the throttle body and vent pipe.
9. Install the coolant vent outlet hose to the throttle body and left-hand radiator tank.
10. Install the fresh air hose to the rocker cover and the throttle body.
11. Install the foul air hose to the throttle body and restricting orifice external connector.





12. Connect the manifold absolute pressure (MAP) sensor connector.
13. Connect the knock sensor connector.
14. Connect the oil pressure sensor connector.





15. Connect the fuel injector connectors (3) to all the fuel injectors.
16. Install the locks (1) to the right and left side ignition coil main connectors and connect the connectors (2).
17. Connect the EVAP canister purge solenoid valve electrical connector (5).
18. Install the harness securing clips (4) to the fuel rail brackets.





19. Install the cable to the throttle body cam lever (1) then install the throttle cable (2) to the throttle body mounting bracket.





20. Install the cable (3) to the retaining clip.





21. Connect the connector to the intake air control (IAC) motor (1).
22. Connect the connector to the throttle position (TP) sensor (2) at the throttle body.





23. Connect the fuel line (4) to the fuel rail.
24. Connect the purge line (1) to the purge valve.





25. Install the intake duct to the vehicle.
26. Secure the intake duct with the hose clamps (1, 3).
27. Connect the air intake sensor connector (2) to the air intake sensor.
28. Install the fuel rail covers.
29. Install the front suspension support brace.
30. Fill the cooling system.
31. Connect the negative battery cable to the battery.