GM 12580678
Intake Manifold

To replace the Intake Manifold (500) for rpo l92 - first design, remove the air cleaner outlet duct, generator, and engine harness retainer nut, and detract the engine harness retainer from the stud and locator. Remove the engine harness electrical connectors from the evap canister purge solenoid , manifold absolute pressure (MAP) sensor , ignition coil harness , left side fuel injectors , throttle actuator , engine coolant temperature (ECT) sensor , and right side fuel injectors . Pull off the engine harness clips and hold the harness aside. Next, reinstall the brake booster vacuum hose clamp, remove the brake booster hose, and purge the evap canister and fuel feed tube. Remove and loosen the Intake Manifold removing the Intake Manifold gaskets (514) and cover the cylinder head passages to avoid entry of debris. If removing your manifold, pull out the brake booster vacuum hose from the Intake Manifold nipple, upper Intake Manifold cover nut and cover, removing the MAP Sensor and evap tube. Unbolt the Throttle Body and Fuel Rail and pull them out, disposing of the Throttle Body Gasket and Fuel Injector lower o-ring seals. For installation, connect the brake booster vacuum hose nipple to the new Intake Manifold, install new Fuel Injector lower o-ring seals pre-greased with clean engine oil, install the Fuel Rail, and tighten bolts with a 10 n.m (89 lb in). Replace a new Throttle Body Gasket, throttle body, and fasten with bolts/nuts at 10 n.m (89 lb in). Reconnect the evap tube and purge solenoid, reattach evap tube quick connect fitting, lubricate and reinstall the MAP Sensor and retainer, and then reinstall the upper Intake Manifold cover and nut until snug. Reattach the brake booster vacuum hose and clamp, apply a new Intake Manifold gaskets (514) before reinstalling the cylinder head passage covers before reinstalling the Intake Manifold (500). Tighten the Intake Manifold bolts (512) first to 5 n.m (44- lb in.), then to 10 n.m (89- lb in.) as specified. Reconnect the pcv hose, fuel feed line , and evap canister purge tube , and tighten brake booster vacuum hose to the booster fittin. Loosen the engine harness branches and replace ect sensor and connect the engine harness clips and connectors tightening them well. At last, install generator and air cleaner outlet duct.

To remove the Intake Manifold (500) for rpo l92-second design, remove the air cleaner outlet duct, the generator and engine harness retainer nut, and then unfasten the engine harness retainer from the stud and locator pin. Disconnect the engine harness connector from the evap canister purge solenoid , manifold absolute pressure (MAP) sensor , ignition coil harness , left side fuel injectors , throttle actuator , right side fuel injectors , and engine coolant temperature (ECT) sensor . Secure and collect the engine harness branches to the cowl panel, brake booster vacuum hose clamp and unsecure the Brake Booster Vacuum Hose from the booster fitting. Disconnect the evap canister purge tube, fuel feed line quick connect fittings, detach the positive crankcase ventilation (PCP) hose, and loosen the Intake Manifold bolts (512). With help, remove the Intake Manifold (500) and close the passages to the cylinder head to avoid debris intrusion. Remove the Intake Manifold gaskets (514) and, in case of changing the manifold, reinstall the Brake Booster Vacuum Hose clamp, disconnect the vacuum hose from the manifold nipple, and disconnect the upper Intake Manifold cover and MAP Sensor. Airport the evap tube quick conn cable sediment, remove evap benign purge solenoid retainer, eradicate the throttle assembly and Fuel Rail eliminating the Throttle Body resort and Fuel Injector bottom sheaves. To install, connect the Brake Booster Vacuum Hose nipple to the new Intake Manifold, install new Fuel Injector lower o-ring seals greased up in the new clean engine oil, and install the Fuel Rail, tightening the bolts up to 10 n.m (89 lb in). Replace with a new Throttle Body Gasket along with the Throttle Body and tighten with bolts/nuts at 10 n.m (89 lb in). Connect the evap tube and purge solenoid back, lubricate the MAP Sensor seal, and mount the MAP Sensor and retainer. Mount the upper Intake Manifold cover and the nut up until it is snug, reconnect the Brake Booster Vacuum Hose and tighten it. Replace new Intake Manifold gaskets (514), remove the covers of the cylinder head passages and install the Intake Manifold (500), then fasten bolts (512) initially to 5 n.m (44 lb in) and then to 10 n.m (89 lb in) accordingly to the specified sequence. Hook back the pcv hose, fuel feed line, and evap canister purge tube. Attaches the Brake Booster Vacuum Hose to the booster fitting, takes off the branches from engine harness and connect the ect sensor. Tighten the engine harness clip to the generator bracket using a bolt assembled with a torque of 9 n.m (80 lb in) reconnect right side fuel injectors, ignition coil harness, and left side fuel injectors install cpa retainers and check as well as install the MAP Sensor and evap canister purge solenoid. Lastly, install the engine harness retainer to the stud and locator pin, tighten the retainer nut to 5 n.m (44 lb in) and reinstall the generator, finishing off with the attachment of the air cleaner outlet duct.

To replace the Intake Manifold for rpos lc9/lmg/ly5/l76 (5.3L and 6.0L), start with the removal of the air cleaner outlet duct and the generator. Next, unload the retainer's nut from the retainer and locate off of the stud. Remove the connections of the engine harness from the evap canister purge solenoid , manifold absolute pressure (MAP) sensor , ignition coil harness , left side fuel injectors , throttle actuator , engine coolant temperature (ECT) sensor , and right side fuel injectors. Pull off the engine harness clips and pull the harness branches out of the path. Remove the Brake Booster Vacuum Hose clamp, the vacuum hose as well as the evap canister purge tube and the fuel feed line. Unfasten and remove the Intake Manifold (500) and discard the gaskets of the Intake Manifold (514). Cover the cylinder head passages in order to prevent debris from entering. When changing Intake Manifold, put the mani flex out on clean ground, remove Brake Booster Vacuum Hose from manifold nipple and remove the upper intake mani cover as well as MAP Sensor. Pull out the evap tube quick connect fitting and dismount. The Throttle Body and Fuel Rail off, then discard the Fuel Injector lower o-ring seals. For installing: in the case that the Intake Manifold was replaced; tighten the Brake Booster Vacuum Hose nipple to the new manifold, do new Fuel Injector lower o-ring seals, lubricate them with fresh engine oil, and add the Fuel Rail, tighten the bolts on 10 n.m (89 lb in). Replace the new Throttle Body Gasket, the Throttle Body, and its bolts/nuts which also need to be tightened to 10 n.m (89 lb in). Replace the evap tube and purge solenoid, attach the evap tube quick connect fitting, lubricate the MAP Sensor seal, and install MAP Sensor and retainer. Reattach the upper Intake Manifold cover, and nut, connect the Brake Booster Vacuum Hose, and install new Intake Manifold gaskets (514) to replace the Intake Manifold (500) that has been placed from before. Tighten all Intake Manifold bolts (512) to 5 n.m (44 lb in), finish tightening to 10 n.m (89 lb in) in the specified sequence. Connect the pcv hose, fuel feed line quick connect fitting , and evap canister purge tube. Tie the engine harness branches, but do not reattach any vacuum hoses, like the Brake Booster Vacuum Hose. Leave its position exactly as when the operation started. Also do not tighten up anything. Connect ect sensor , right side fuel injectors , throttle actuator , ignition coil harness , and MAP Sensor to the engine harness electrical connectors. Position the engine harness retainer to the stud and locator pin, then fasten it with the nut to 5 n.m (44 lb in) and reinstall both the generator and the air cleaner outlet duct.

Install the fuel injectors and the throttle body.

Position and install the PCV hose, connect the fuel feed line and EVAP canister purge tube quick connect fittings, and reattach the brake booster vacuum hose to the booster fitting.

Finally, reinstall the generator and air cleaner outlet duct.

First to 3 N.m (27 lb in), then to 12 N.m (106 lb in), and finally to 15 N.m (11 lb ft).

Disconnect the control port injector module, EVAP canister purge solenoid valve, and manifold absolute pressure (MAP) sensor.