Intake Manifold Replacement - Lower

Removal Procedure

Important: The lower intake manifold gaskets and seals are reusable. Replace only the gaskets and seals if they are damaged.

1. Remove the engine cover from the vehicle.
2. Drain the cooling system.
3. Disconnect the battery negative cable from the battery. Refer to Battery Cable Replacement (Battery Cable Negative) in Starting and Charging.
4. Remove the upper intake manifold from the lower intake manifold.





5. Remove the suction line from Air Conditioning from the A/C compressor. Refer to Compressor Hose Assembly Replacement in Heating and Air Conditioning.

Important: Mark the relationship of the distributor housing to the rotor for proper reinstallation.

6. Remove the distributor from the lower intake manifold.
7. Remove the MAP sensor from the lower intake manifold.
8. Remove the radiator hose from the thermostat.
9. Remove the thermostat housing from the lower intake manifold from the engine block.
10. Remove the heater hoses from the heater core.
11. Remove the coolant bypass hose from the lower intake manifold and the water pump.
12. Remove the retaining bolts for the fuel rail. Refer to Fuel Hose/Pipes Replacement (Engine Compartment) in Powertrain Management.
13. Remove the fuel rail from the lower intake manifold. Refer to Fuel Hose/Pipes Replacement (Engine Compartment) in Powertrain Management.





14. Remove the lower intake manifold bolts from the engine head.
15. Remove the lower intake manifold from the cylinder head.
16. Remove the lower intake manifold gaskets and seals from the cylinder head.
17. Clean all sealing surfaces of oil and grease.

Installation Procedure





1. Install the lower intake manifold gaskets to the cylinder head with THIS SIDE UP stamped facing up.
2. Install the lower intake manifold to the engine block.
3. Apply the Loctite (R) 242 GM P/N 12345382 to the lower intake manifold bolts.

Notice: Refer to Fastener Notice in Service Precautions.





4. Install the lower intake manifold bolts to the engine head.
5. Tighten
^ Tighten the bolts in sequence to 30 Nm (22 ft. lbs.).
6. Re-tighten the bolts in sequence to 40 Nm (30 ft. lbs.).
7. Install the fuel rail to the lower intake manifold.
8. Install the fuel rail retaining bolts.
9. Install the coolant bypass hose to the water pump.
10. Install the heater hoses to the lower intake manifold.
11. Install the thermostat housing to the lower intake manifold from the engine block.





12. Install the MAP sensor to the lower intake manifold.
13. Install the radiator hose to the thermostat housing.
14. Install the distributor to the engine block. Refer to Distributor Installation.
15. Install the suction hose to the A/C compressor. Refer to Compressor Hose Assembly Replacement in Heating and Air Conditioning.





16. Install the upper intake manifold to the lower intake manifold.
17. Install the discharge line to the A/C compressor.
18. Refill the cooling system.
19. Connect the battery negative cable to the battery.
20. Install Engine Cover.