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Home >> Chevrolet >> 2001 >> Lumina V6-3.1L VIN J >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Intake Manifold >> Service and Repair >> Upper Intake Manifold Replacement

Upper Intake Manifold Replacement

Intake Manifold Replacement (Upper)

Removal Procedure

Important: This engine uses a sequential multiport fuel injection system. Connect the injector wiring harness connectors to their appropriate fuel injector or exhaust emissions and engine performance may be seriously affected. For the correct injector wiring harness connector-to-fuel injector connection procedure, refer to Engine Electrical.

1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure.
2. Disconnect the vacuum hose connection from the throttle body air inlet duct.
3. Disconnect the wiring harness connection from the Intake Air Temperature (IAT) sensor in the throttle body air inlet duct. Refer to IAT Sensor Replacement in Powertrain Management.
4. Remove the throttle body air inlet duct.
5. Drain the engine coolant from the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
6. Remove the accelerator control and cruise control cables with bracket from the throttle body. Remove the wiring harness from the retainer. Refer to Accelerator Controls Cable Bracket Replacement in Powertrain Management.
7. Disconnect the following wiring harness connectors from the throttle body:
- Throttle Position (TP) sensor
- Idle air control (IAC) valve
8. Disconnect the (left) front spark plug wires. Refer to Spark Plug Wire Harness Replacement.
9. Disconnect the wiring harness attachment clips.
- Camshaft Position (CMP) sensor wiring harness
- Left hand spark plug wire harness
- Engine wiring harness
10. Remove the nut from the coolant pipe to the throttle body.
11. Disconnect the thermostat bypass pipe coolant hoses from the throttle body. Refer to Heating and Air Conditioning.
12. Remove the engine mount struts. Refer to Engine Mount Strut Bracket Replacement (Left) and Engine Mount Strut Bracket Replacement (Right).
13. Rotate the engine forward for access.
14. Disconnect the right spark plug wire retaining clips.
15. Remove the spark plug wires at the coil pack.
16. Remove the ignition coil bracket with the coils, the purge solenoid, the vacuum canister solenoid, the vacuum lines, and the electrical connections. Refer to Ignition Control Module Replacement and EVAP Canister Purge Valve Replacement in Powertrain Management.





17. Disconnect the vacuum hose at the manifold air pressure (MAP) sensor and upper intake manifold.
18. Remove the Manifold Air Pressure (MAP) sensor and the bracket. Refer to MAP Sensor Replacement in Powertrain Management.





19. Disconnect the emission control vacuum harness.
20. Disconnect the vacuum hose connections from the upper intake manifold.
- Vacuum booster hose
- Automatic transaxle vacuum modulator hose
- Heater and air conditioning vacuum source hose
- Fuel pressure regulator
21. Remove the drive belt. Refer to Drive Belt Replacement.
22. Remove the front generator brace. Refer to Generator Brace Replacement (Front).
23. Remove the rear generator brace. Refer to Generator Brace Replacement (Rear).





24. Remove the Exhaust Gas Recirculation (EGR) valve. Refer to EGR Valve Replacement in Powertrain Management.





25. Remove the right hand upper intake manifold bolts and studs.





26. Remove the left hand upper intake manifold bolts.
27. Remove the upper intake manifold.





28. Remove the upper intake manifold gasket.





29. If replacing the upper intake manifold, remove the throttle body. Refer to Throttle Body Assembly Replacement in Powertrain Management.
30. Clean the seal surfaces on the manifold with degreaser.

Installation Procedure





1. If removed, install the throttle body. Refer to Throttle Body Assembly Replacement in Powertrain Management.




2. Install the upper intake manifold gasket.





3. Install the upper intake manifold.
4. Loosely install the left hand upper intake manifold bolts.





5. Loosely install the right hand upper intake manifold bolts and studs.

Notice: Refer to Fastener Notice in Service Precautions.

6. Install the upper intake manifold bolts and studs.

Tighten
Tighten the upper intake manifold bolts and studs to 25 N.m (18 lb ft).





7. Install the exhaust gas recirculation (EGR) valve. Refer to EGR Valve Replacement in Powertrain Management.
8. Install the rear generator brace. Refer to Generator Brace Replacement (Rear).
9. Install the front generator brace. Refer to Generator Brace Replacement (Front).
10. Connect the vacuum hose connections to the upper intake manifold.
- Vacuum booster hose
- Automatic transaxle vacuum modulator hose
- Heater and air conditioning vacuum source hose
- Fuel pressure regulator





11. Connect the emission control vacuum harness.
12. Install the manifold air pressure (MAP) sensor and bracket. Refer to MAP Sensor Replacement in Powertrain Management.





13. Connect the vacuum hose at the manifold air pressure (MAP) sensor and the upper intake manifold.
14. Install the ignition coil bracket with the coils, the purge solenoid, the vacuum canister solenoid, the spark plug wire retainers, the plug wires at the ignition module, the vacuum lines, and the electrical connections. Refer to Ignition Control Module Replacement and EVAP Canister Purge Valve Replacement in Powertrain Management.
15. Return the engine to the proper position.
16. Install the engine mount struts. Refer to Engine Mount Strut Bracket Replacement (Left) and Engine Mount Strut Bracket Replacement (Right).
17. Connect the thermostat bypass pipe coolant hoses to the throttle body.
18. Install coolant pipe nut to throttle body.
19. Connect the wiring harness attachment clips.
- Camshaft position (CMP) sensor wiring harness
- Left hand spark plug wire harness
- Engine wiring harness
20. Connect the left hand spark plug wires. Refer to Spark Plug Wire Harness Replacement.
21. Connect the wiring harness connectors to the throttle body.
- Throttle position (TP) sensor
- Idle air control (IAC) valve
22. Install the accelerator control and cruise control cables with bracket to the throttle body. Install the wiring harness to the retainer. Refer to Throttle Body Assembly Replacement in Powertrain Management.
23. Fill the cooling system with engine coolant. Refer to Draining and Filling Cooling System in Cooling System.
24. Install the throttle body air inlet duct.
25. Connect the wiring harness connection to the intake air temperature (IAT) sensor in the throttle body air inlet duct. Refer to MT Sensor Replacement.
26. Connect the vacuum hose connection to the throttle body air inlet duct.
27. Connect the battery ground (negative) cable. Refer to Refer to Battery Negative Cable Disconnect/Connect Procedure.
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