Intake Manifold Replacement - Lower

Removal Procedure

Notice: Engine Code K has two bolts which are hidden beneath the upper intake. These bolts are located in the right front and left rear corners of the lower intake manifold. It is necessary to remove the upper intake manifold to service the lower intake.

Caution: Refer to Battery Disconnect Caution in Service Precautions.

1. Disconnect the negative battery cable.
2. Remove the upper intake manifold.
3. Drain the Cooling System. Refer to Draining and Filling under Cooling System.
4. Remove the upper radiator hose.
5. Remove the generator.
6. Remove the drive belt tensioner. .
7. Remove the EGR valve outlet pipe.





8. Remove the lower intake manifold bolts.
9. Remove the lower intake manifold.

Installation Procedure

Important: In order to complete the installation, observe the following assembly tips:
^ Clean the cylinder block, heads and the intake manifold sealing surface of all oil with a suitable solvent.
^ Clean the intake manifold bolts and bolt holes of adhesive compound.
^ Apply thread locking compound GM P/N 12345739 or equivalent to the intake manifold bolt threads before assembly.





1. Install the lower intake manifold.

Notice: Refer to Fastener Notice in Service Precautions.





2. Install the lower intake manifold bolts.
^ Tighten the bolts in sequence to 15 Nm (11 ft. lbs.).

3. Connect the negative battery cable.
4. Install the EGR valve outlet pipe.
5. Install the drive belt tensioner.
6. Install the generator.
7. Install the upper radiator hose.
8. Fill the cooling system. Cooling System.
9. Install the upper intake manifold.
10. Connect the negative battery cable.