Lower Intake Manifold Replacement

Intake Manifold Replacement - Lower

Removal Procedure

1. Remove the upper intake manifold.
2. Remove the generator brace.





3. Remove the drive belt tensioner with the mounting bracket and the heater water bypass inlet pipe.





4. Remove the exhaust gas recirculation (EGR) outlet pipe bolt from the lower intake manifold.





5. Remove the radiator inlet hose from the water outlet housing.





6. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
7. Remove the right upper engine mount strut bracket.





8. Remove the generator brace bracket bolts.
9. Remove the generator brace bracket.





10. Remove the lower intake manifold bolts.
11. Remove the lower intake manifold.





12. Remove the lower intake manifold seals.





13. Remove the lower intake manifold gaskets.





14. If replacing the lower intake manifold, remove the water outlet housing bolt and stud, the water outlet housing, the gasket and the thermostat.
15. If replacing the lower intake manifold, remove the ECT sensor.
16. Inspect the flatness of inlet flanges.
17. Clean the intake manifold mating surfaces.
18. Clean the intake manifold bolts and bolt holes of adhesive compound.

Installation Procedure

Notice: Refer to Fastener Notice in Service Precautions.

1. If removed, install the ECT sensor.

Tighten
Tighten the ECT sensor to 25 Nm (18 lb ft).





2. If removed, install the thermostat, the gasket, and the water outlet housing.
3. Install the water outlet housing bolt and the stud.

Tighten
Tighten the bolt and stud to 27 Nm (20 lb ft).





4. Install the lower intake manifold gaskets.





5. Apply sealer GM P/N 12346286 (Canadian P/N 10953472) or equivalent to the ends of the intake manifold seals.
6. Install the lower intake manifold seals.





7. Install the lower intake manifold.





8. Install the lower intake manifold bolts (1-12). Apply thread lock compound GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the two hidden bolts and ensure they are installed.

Tighten
Tighten the lower intake manifold bolts in sequence to 15 Nm (11 lb ft).





9. Install the generator brace bracket.
10. Install the generator brace bracket bolts.

Tighten
Tighten the bolts to 50 Nm (37 lb ft).

11. Install the right upper engine mount strut bracket.





12. Connect the ECT sensor electrical connector.





13. Install the radiator inlet hose to the water outlet housing.





14. Install the EGR outlet pipe to the lower intake manifold.
15. Install the EGR outlet pipe bolt to the lower intake manifold.

Tighten
Tighten the bolt to 29 Nm (21 lb ft).





16. Install the drive belt tensioner.
17. Install the generator brace.
18. Install the upper intake manifold.
19. Inspect for leaks.