Intake Manifold Replacement (Upper Intake Manifold)

Intake Manifold Replacement (Upper Intake Manifold)

Removal Procedure

1. Disconnect the battery negative cable from the battery. Refer to Battery Cable Replacement (Negative Cable to Engine) Battery Cable Replacement (Negative Cable to Engine)Battery Cable Replacement (Positive Cable) Service and RepairBattery Cable Replacement (Negative Cable to Frame) Battery Cable Replacement (Negative Cable to Frame) in Engine Electrical.
2. Remove the intake air resonator from the throttle body. Refer to Air Cleaner Outlet Front Duct Replacement Air Cleaner Outlet Front Duct Replacement in Engine Controls.
3. Remove the air cleaner intake duct from the throttle body. Refer to Air Cleaner Outlet Front Duct Replacement Air Cleaner Outlet Front Duct Replacement in Engine Controls.
4. Remove the PCV Valve from the valve rocker arm cover to the cylinder head.




5. Remove the crankcase vent tube from the throttle body.
6. Remove the EGR pipe from the upper intake manifold. Refer to Exhaust Gas Recirculation Pipe Replacement Service and Repair in Engine Controls.
7. Remove the left and right side secondary AIR injection pipe. If so equipped.
8. Remove the throttle body from the upper intake manifold. Refer to Throttle Body Assembly Replacement (SFI) Service and Repair.
9. Remove the EVAP canister solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement Service and Repair in Engine Controls.
10. Remove the upper intake manifold bolts.
11. Remove the upper intake manifold and gaskets.
12. Clean the excessive carbon deposits from the exhaust and the EGR valve passages.

Installation Procedure




1. Install the upper intake manifold gaskets.
2. Install the upper intake manifold.

Important: Failure to follow the procedure listed, could cause driveability problem.


3. Coat a minimum of eight threads of the bolt with thread locking sealant GM P/N 12345493.

Notice: Refer to Fastener Notice in Cautions and Notices.

4. Install the upper intake manifold bolts.

1. Tighten the bolts in sequence to 8 Nm (71 lb in).
2. Retighten the bolts in sequence to 18 Nm (13 lb ft).

5. Install the EGR valve if necessary. Refer to Exhaust Gas Recirculation Valve Replacement Service and Repair in Engine Controls.




6. Install the EGR pipe to the upper intake manifold. Refer to Exhaust Gas Recirculation Pipe Replacement Service and Repair in Engine Controls.
7. Install the left and right side secondary AIR injection pipes. If so equipped.
8. Install the EVAP canister solenoid valve to the intake manifold. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement Service and Repair in Engine Controls.
9. Install the throttle body to the upper intake manifold. Refer to Throttle Body Assembly Replacement (SFI) Service and Repair.




10. Install the PCV valve to the valve rocker arm cover to the cylinder head.
11. Install crankcase vent tube to the valve rocker arm cover.
12. Install the air cleaner intake duct to the throttle body. Refer to Air Cleaner Outlet Front Duct Replacement Air Cleaner Outlet Front Duct Replacement in Engine Controls.
13. Install the intake air resonator to the throttle body. Refer to Air Cleaner Outlet Front Duct Replacement Air Cleaner Outlet Front Duct Replacement in Engine Controls.
14. Connect the battery negative cable to the batter. Refer to Battery Cable Replacement (Negative Cable to Engine) Battery Cable Replacement (Negative Cable to Engine)Battery Cable Replacement (Positive Cable) Service and RepairBattery Cable Replacement (Negative Cable to Frame) Battery Cable Replacement (Negative Cable to Frame) in Engine Electrical.
15. Close the hood.