Intake Manifold Replacement

Intake Manifold Replacement

Removal Procedure

1. 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 throttle body.
2. Remove the fuel injectors.





3. Disconnect the following electrical connectors:
^ Manifold absolute pressure (MAP) sensor (1)
^ Knock sensor (2)
4. Remove the knock sensor harness electrical connector from the intake manifold.
5. Set the electrical harness aside.





6. If equipped with vacuum assisted brakes, remove the vacuum brake booster hose from the rear of the intake manifold.





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





8. Remove the MAP sensor (1) from the intake manifold.





9. Remove the evaporative emission (EVAP) purge solenoid vent tube by performing the following:
1. Remove the EVAP tube end from the solenoid (1).
2. Remove the EVAP tube end from the vapor pipe (2).





10. Remove the EVAP purge solenoid bolt (2), solenoid (3), and isolator (1) from the intake manifold.





11. Loosen the intake manifold bolts.
12. Remove the intake manifold.





13. Remove the intake manifold gaskets (1) from the intake manifold.
14. Discard the old intake manifold gaskets.
15. If required, 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) band 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.

Tighten 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. Install the EVAP purge solenoid (3), isolator (1), and bolt (2) to the intake manifold.
^ Tighten the bolt to 10 Nm (89 inch lbs.).





6. Install the EVAP purge solenoid vent tube to the solenoid (1) and vapor pipe (2).





7. Important: Lightly coat the MAP sensor seal with clean engine oil before installing.

Install the MAP sensor (1) to the intake manifold.





8. Install the PCV hose.





9. If equipped with vacuum assisted brakes, install the vacuum brake booster hose to the rear of the intake manifold.
10. Route the electrical harness into position over the engine.





11. Connect the knock sensor harness electrical connector to the intake manifold.
12. Connect the following electrical connectors.
^ MAP sensor (1)
^ Knock sensor (2)
13. Install the fuel injectors.
14. Install the throttle body.