Intake Manifold Replacement (Upper)

REMOVAL PROCEDURE

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

1. Disconnect the battery negative cable.
2. Remove the air cleaner assembly.
3. Remove the vacuum brake booster hose, if equipped.
4. Disconnect the throttle and cruise control cables (if equipped).
5. Remove the throttle cable bracket and set it aside.
6. Remove the following electrical connectors:
- The SCP injector harness connector
- The canister purge solenoid
- The ignition coil
- The ignition control module (ICM)
- The generator
- The idle air control (IAC) motor
- The oxygen (02 sensor)
- The exhaust gas recirculation (EGR) valve
- The engine coolant temperature (ECT) sensor

7. Disconnect the fuel pipes from the fuel pipes.
8. Remove the distributor cap and reposition it out of the way.
9. Remove the PCV valve.





10. Remove the wiring support bracket at the rear of the manifold.
11. Remove the canister purge valve.
12. Remove the studs holding the upper intake manifold.
13. Remove the upper intake manifold. Refer to Intake Manifold Disassemble under Engine Unit Repair.
14. Clean all surfaces. Refer to Intake Manifold Clean and Inspect under Engine Unit Repair.

INSTALLATION PROCEDURE





1. Install the NEW upper intake manifold to lower intake manifold gasket (3) into the groove of the upper intake manifold (2).
2. Install the upper intake manifold (2) onto the lower intake manifold (6).

3. If reusing the fasteners, apply threadlock GM P/N 12345382 or equivalent to the threads of the upper intake manifold attaching studs (1).

Sequence:

3. Install the upper intake manifold studs (1).
3.1. Tighten the upper intake manifold studs on the first pass to 5 Nm (44 inch lbs.).
3.2. Tighten the upper intake manifold studs on the second pass to 10 Nm (89 inch lbs.).





4. Install the canister purge valve.

NOTICE: Refer to Fastener Notice in Service Precautions.





5. Install the wiring support bracket at the rear of the manifold.
Tighten the nut to 12 Nm (106 inch lbs.).
6. Install the PCV valve.
7. Install the distributor cap.
8. Connect the fuel pipes to the rear of the engine.
9. Connect the electrical connectors.
10. Install the throttle cable bracket.
11. Connect the throttle cable and the cruise control cable, if equipped.
12. Install the vacuum brake booster hose, it equipped.
13. Install the air cleaner assembly.
14. Connect the battery negative cable.