Intake Manifold Replacement - Lower

Intake Manifold Replacement- Lower
Removal Procedure





1. Disconnect the negative battery cable.
2. Remove the upper intake manifold.
3. Remove the left valve rocker arm cover.
4. Remove the right valve rocker arm cover.
5. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.





6. Disconnect and remove the fuel injector and the Manifold Absolute Pressure (MAP) sensor wiring harnesses.





7. Remove the fuel pipe clip bolt.





8. Remove the fuel pipe clip.





9. Remove the fuel feed pipe from the fuel injector rail.





10. Remove the fuel return pipe from the fuel injector rail.





11. Remove the fuel injector rail.
12. Remove the power steering pump from the front engine cover and reposition.





13. Remove the heater inlet pipe nut.
14. Remove the heater inlet pipe with heater hose from the lower intake manifold and reposition.
15. Remove the radiator inlet hose from the engine.





16. Remove the thermostat bypass hose from the thermostat bypass pipe and lower intake manifold pipe.





17. Remove the lower intake manifold bolts.
18. Remove the lower intake manifold.
19. Remove the valve rocker arms and pushrods.





20. Remove the lower intake manifold gaskets and seals.
21. Clean the lower intake manifold gasket mating surfaces.
22. Remove and clean all the RTV sealant from the lower intake manifold and the engine block (1).





23. Remove the ECT sensor.





24. Remove the water outlet bolts.
25. Remove the water outlet.





26. Remove the thermostat.

Installation Procedure





1. Install the thermostat.





2. Install the water outlet.

Notice: Refer to Fastener Notice in Service Precautions.

3. Install the water outlet bolts.
^ Tighten the bolts to 25 Nm (18 ft. lbs.).





4. Install the ECT sensor.
^ Tighten the sensor to 25 Nm (18 ft. lbs.).
5. Apply 8 - 12 mm (0.08 - 0.11 inch) bead of RTV Sealer, GM P/N 12346286 (Canadian P/N 10953472) or equivalent, on each ridge where front and rear of the lower intake manifold contact the engine block (1).





6. Install the lower intake manifold gaskets.
7. Install the valve rocker arms and pushrods.





8. Install the lower intake manifold.
9. Apply sealant, GM P/N 12345382 (Canadian P/N 10953489) to the threads of the bolts.





Notice: An oil leak may result if the vertical bolts are not tightened before the diagonal bolts.

10. Install the lower intake manifold bolts (1, 2).
10.1. Tighten the center lower intake manifold bolts (1) to 7 Nm (62 inch lbs.).
10.2. Tighten the corner lower intake manifold bolts (2) to 7 Nm (62 inch lbs.).
10.3. Tighten the center lower intake manifold bolts (1) to 13 Nm (115 inch lbs.).
10.4. Tighten the corner lower intake manifold bolts (2) to 25 Nm (18 foot lbs.).





11. Install the thermostat bypass hose to the thermostat bypass pipe and lower intake manifold pipe.
12. Install the heater inlet pipe nut.
^ Tighten the nut to 25 Nm (18 ft. lbs.).
13. Install the radiator inlet hose to the engine.





14. Install the heater inlet pipe and heater hose to the lower intake manifold.
15. Install the power steering pump to the front engine cover.





16. Install the fuel injector rail.





17. Install the fuel return pipe to the fuel injector rail.





18. Install the fuel feed pipe to the fuel injector rail.





19. Install the fuel pipe clip.





20. Install the fuel pipe clip bolt.
^ Tighten the bolt to 8 Nm (71 inch lbs.).





21. Install and connect the fuel injector and the MAP sensor wiring harnesses.





22. Connect the ECT sensor electrical connector.
23. Install the right valve rocker arm cover.
24. Install the left valve rocker arm cover.
25. Install the upper intake manifold.
26. Connect the negative battery cable.
27. Inspect for leaks.