Upper Intake Manifold Replacement
Intake Manifold Replacement-UpperRemoval Procedure
1. Remove the top half of the air cleaner assembly.
2. Drain the cooling system.
3. Remove the brake vacuum pipe at the plenum.
4. Disconnect the fuel pressure regulator vacuum hose from the fuel pressure regulator and the PCV valve.
5. Remove the electronic ignition coil and module assembly.
6. Remove throttle cable bracket with cables.
7. Remove the EVAP canister purge solenoid.
8. Disconnect the Throttle Position (TP) sensor.
9. Disconnect the Idle Air Control (IAC) sensor.
10. Disconnect the fuel injector harness.
11. Remove the Manifold Absolute Pressure (MAP) sensor (1).
12. Remove EGR pipe.
13. Remove inlet and outlet hoses from throttle body (1).
14. Remove the upper intake manifold bolts.
15. Remove the upper intake manifold and gaskets.
16. Clean the gasket surfaces.
Installation Procedure
1. Install the upper intake manifold gaskets on the manifold.
Notice: Refer to Fastener Notice in Service Precautions.
2. Apply thread lock GM P/N 12345382 to the threads of the bolts.
Install the upper intake manifold bolts.
^ Tighten the upper intake manifold bolts to 25 Nm (18 ft. lbs.).
3. Install the MAP sensor (1).
4. Install EGR pipe.
5. Install inlet and outlet hoses from throttle body (1).
6. Install the vacuum hose (1),to the fuel pressure regulator (3) and the crankcase ventilation valve (2).
7. Connect the TP sensor.
8. Connect the IAC.
9. Connect the fuel injector harness.
10. Install the EVAP canister purge solenoid.
11. Install the electronic ignition coil and module assembly.
12. Install throttle cable bracket and cables to throttle body.
13. Install the top half of the air cleaner assembly.
14. Install the brake vacuum pipe.
15. Fill the cooling system.
16. Inspect for proper fluid levels.
17. Inspect for leaks.