Intake Manifold Replacement - Lower

Removal Procedure

Caution: Refer to Battery Disconnect Caution in Service Precautions.

1. Disconnect the negative battery cable.





2. Remove the upper intake manifold. Refer to Intake Manifold Replacement.
3. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
4. Remove the upper radiator hose. Refer to Radiator Hose Replacement-Outlet in Cooling System.
5. Remove the generator. Refer to Generator Replacement.
6. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement.
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. Refer to Drive Belt Tensioner Replacement.
6. Install the generator. Refer to Generator Replacement.
7. Install the upper radiator hose. Refer to Radiator Hose Replacement-Outlet in Cooling System.
8. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
9. Install the upper intake manifold. Refer to Intake Manifold Replacement.
10. Connect the negative battery cable.