Intake Manifold Replacement

Intake Manifold Replacement

Removal Procedure
1. Disconnect the negative battery cable.

2. Important: The intake manifold, throttle body, fuel rail, and injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.

Remove the air cleaner outlet duct.
3. Relieve the fuel system pressure.





4. Disconnect the air conditioning (A/C) compressor pressure switch electrical connector (2).
5. Remove the harness clip (1) from the cylinder head.





6. Disconnect the electrical connector (1) from the mass air flow (MAF) intake air temperature (IAT) sensor.
7. Remove the harness clips from the fuel rail.





8. Disconnect the following electrical connectors:
^ Main coil (1)
^ Electronic throttle control (ETC) (2)
^ Fuel injectors (3)





9. Perform the following steps in order to disconnect the fuel injector electrical connector.
1. Mark the connectors to their corresponding injectors to ensure correct reassembly.
2. Pull the connector position assurance (CPA) retainer (2) on the connector up one click.
3. Push the tab (1) on the connector in.
4. Disconnect the fuel injector electrical connector.
5. Repeat the steps for each injector electrical connector.





10. Disconnect the generator electrical connector.





11. Disconnect the following electrical connectors:
^ Evaporative emission (EVAP) purge solenoid (1)
^ Knock sensor (KS) (2)
^ Manifold absolute pressure (MAP) sensor (3)
^ Main coil (5)
^ Fuel injectors (4)
12. Remove the electrical harness clips from the fuel rail.
13. Remove the KS harness electrical connector from the intake manifold.





14. Remove the positive crankcase ventilation (PCV) hose.





15. Remove the heater water shutoff valve actuator inlet hose from the intake manifold.





16. Remove the EVAP purge solenoid vent tubes (1, 2).





17. Disconnect the fuel feed pipe (3) from the fuel rail (2).





18. Remove the vacuum brake booster hose from the rear of the intake manifold.





19. Remove the upper engine wire harness retainer nut (1).
20. Reposition the upper engine wire harness aside.





21. Remove the intake manifold bolts.
22. Remove the intake manifold.





23. Remove the intake manifold gaskets (1) from the intake manifold.
24. Discard the old intake manifold gaskets.
25. If necessary, clean and inspect the intake manifold.

Installation Procedure





1. Install NEW intake manifold gaskets (1) to the intake manifold.





2. Install the intake manifold.
3. Apply a 5 mm (0.20 inch) bead of threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the intake manifold bolts.





4. Notice: Refer to Fastener Notice in Service Precautions.

Install the intake manifold bolts.
1. Tighten the bolts a first pass in sequence to 5 Nm (44 inch lbs.).
2. Tighten the bolts a final pass in sequence to 10 Nm (89 inch lbs.).





5. Route the electrical harness into position over the engine.
6. Install the engine harness bracket nut (1).
Tighten the nut to 10 Nm (89 inch lbs.).





7. Install the vacuum brake booster hose to the rear of the intake manifold.





8. Connect the fuel feed pipe (3) to the fuel rail (2).





9. Install the EVAP purge solenoid vent tubes (1, 2).





10. Install the heater water shutoff valve actuator inlet hose to the intake manifold.





11. Install the PCV hose.
12. Install the KS harness electrical connector to the intake manifold.





13. Connect the following electrical connectors:
^ EVAP purge solenoid (1)
^ KS (2)
^ MAP sensor (3)
^ Main coil (5)
^ Fuel injectors (4)





14. Perform the following steps in order to connect the fuel injector electrical connectors.
0. Install the connectors to their corresponding injectors to ensure correct reassembly.
1. Connect the fuel injector electrical connector.
2. Push the CPA retainer (2) on the connector in one click.
3. Repeat the steps for each injector electrical connector.
15. Install the harness clips to the fuel rail.





16. Connect the generator electrical connector.





17. Connect the following electrical connectors:
^ Main coil (1)
^ ETC (2)
^ Fuel injectors (3)
18. Install the electrical harness clips to the fuel rail.





19. Connect the A/C compressor pressure switch electrical connector (2).
20. Install the harness clip (1) to the cylinder head.





21. Connect the MAF/IAT sensor electrical connector (1).
22. Install the air cleaner outlet duct.
23. Install the fuel fill cap.
24. Connect the negative battery cable.
25. Use the following procedure in order to inspect for leaks:
0. Turn the ignition ON, with the engine OFF, for 2 seconds.
1. Turn the ignition OFF for 10 seconds.
2. Turn the ignition ON, with the engine OFF.
3. Inspect for fuel leaks.