Upper Intake Manifold Replacement

Removal Procedure





1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Service Precautions.
2. Carefully remove the throttle body air inlet duct.
3. Drain the engine coolant from the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
4. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield replacement.
5. Remove the right spark plug wires. Refer to Spark Plug Wire Harness Replacement in Powertrain Management.
6. Disconnect the evaporative emissions canister purge solenoid valve wiring harness connector. Refer to EVAP Canister Purge Valve Replacement in Powertrain Management.
7. Relieve the fuel pressure. Refer to Fuel Pressure Relief Procedure in Powertrain Management.
8. Remove the fuel rail. Refer to Fuel Rail Assembly Replacement in Powertrain Management.
9. Remove the brake booster hose from the vacuum source manifold in the upper intake manifold. Refer to Vacuum Brake Booster Hose Replacement in Hydraulic Brakes.
10. Remove the EGR shield from the upper intake manifold.





11. Remove the throttle body support bracket.





12. Disconnect the MAP sensor electrical connector. Refer to MAP Sensor Replacement in Powertrain Management.
13. Remove the upper intake manifold bolts.
14. Clean the upper intake manifold bolt threads.
15. Remove the upper intake manifold.





16. Remove the upper-to-lower intake manifold carrier gasket from the upper intake manifold.
17. If the upper intake manifold is being replaced, remove the throttle body. Refer to Throttle Body Assembly Replacement in Powertrain Management.





18. If the upper intake manifold is being replaced, remove the vacuum source manifold.

Installation Procedure





1. If the upper intake manifold is being replaced, install the vacuum source manifold.
2. If the upper intake manifold is being replaced, install the throttle body. Refer to Throttle Body Assembly Replacement in Powertrain Management.





3. Install the upper-to-lower intake manifold carrier gasket to the upper intake manifold.





4. Carefully place the upper intake manifold onto the lower intake manifold. Make sure that the alignment pins in the upper intake manifold align with the holes in the lower intake manifold.
5. Install the upper intake manifold.
6. Apply thread lock compound GM P/N 12345382 or equivalent, to the bolt threads before assembly.

Notice: Refer to Fastener Notice in Service Precautions.





7. Install the upper intake manifold bolts (1-10).
Tighten the upper intake manifold bolts in sequence to 10 Nm (89 inch lbs.).
8. Connect the MAP sensor electrical connector. Refer to MAP Sensor Replacement in Powertrain Management.





9. Install the throttle body support bracket.
10. Install the throttle body support bracket bolts.
Tighten the throttle body support bracket bolts to 10 Nm (89 inch lbs.).





11. Install the EGR shield to the upper intake manifold.
12. Install the brake booster hose to the vacuum source manifold in the upper intake manifold. Refer to Vacuum Brake Booster Hose Replacement in Hydraulic Brakes.
13. Install the fuel rail. Refer to Fuel Rail Assembly Replacement in Powertrain Management.
14. Connect the evaporative emissions canister purge solenoid valve wiring harness connector. Refer to EVAP Canister Purge Valve Replacement in Powertrain Management.
15. Install the right (rear) spark plug wires. Refer to Spark Plug Wire Harness Replacement in Powertrain Management.
16. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement.
17. Fill the cooling system with engine coolant. Refer to Draining and Filling Cooling System in Cooling System.
18. Carefully install the throttle body air inlet duct.
19. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Service Precautions.
20. Inspect for the proper fluid levels.
21. Inspect for fluid or vacuum leaks.