GM 12597600
Intake Manifold

High voltage service disconnect and disconnection of the battery ground cable must both occur before starting the Intake Manifold replacement. The installment of manifold replacement demands the removal of three components: air cleaner outlet duct, engine harness retainer nut and engine harness retainer from stud and locator pin. The engine harness electrical connectors must be disconnected from seven crucial components: evap canister purge solenoid, manifold absolute pressure sensor and ignition coil harness in addition to left side fuel injectors, throttle actuator and right side fuel injectors and engine Coolant Temperature Sensor. Unplug the generator control module electrical connector while using zip ties to fasten the engine harness branches above the work area. You must separate the evap canister purge tube from its quick connector as well as the fuel feed tube from its quick connector. First remove the positive crankcase ventilation (PCV) hose followed by loosening the Intake Manifold bolts (512) until you can extract the Intake Manifold (500). Protect the cylinder head passages while discarding and removing new Intake Manifold gaskets (514). Clean and inspect the Intake Manifold. Start by removing the upper Intake Manifold cover nut and the upper Intake Manifold cover then remove the MAP Sensor retainer and the MAP Sensor and discard the MAP Sensor seal. First disconnect the fast release of the evap tube at the Intake Manifold then release the retainer for the evap canister purge solenoid while removing the Throttle Body together with its gasket. Remove the Fuel Rail bolts before lifting the rail evenly to extract all injectors. The lower o-ring seals on the fuel injectors need immediate disposal. Begin by applying clean engine oil to new Fuel Injector lower o-ring seals before installing them onto the injectors. Then fasten the Fuel Rail to 10 nm (89 lb in) torque. Place a fresh Throttle Body Gasket onto the Throttle Body assembly with bolts/nuts secured to 10 nm torque (89 lb in). After installation of the evap tube and purge solenoid you must secure the solenoid to the Fuel Rail bracket before you connect the evap tube quick connect fitting at the Intake Manifold. Use engine oil to lubricate the MAP Sensor seal after which you should install the sensor along with a fresh seal and fasten it with the retainer. Begin by tightening the upper Intake Manifold cover and nut before adding new Intake Manifold gaskets (514) and removing the cylinder head passage covers to install the Intake Manifold (500). Apply a 5 mm (0.20 in) band of threadlock gm p/n 12345382 (Canadian P/N 10953489) to the Intake Manifold bolts (512) threads, install the bolts finger tight, and tighten them to specifications: the bolt torques start at 5 nm (44 lb in) during the first stage then finish at 10 nm (89 lb in). Position the pcv hose before connecting the fuel feed line quick connect fitting to the Fuel Rail as well as the evap canister purge tube quick connect fitting to the evap canister purge solenoid. Attach the engine harness electrical connector to the ect sensor before installing the engine harness clip to the generator bracket and tightening the bolt to 9 nm (80 lb in). The installation requires connecting the generator control module electrical connector along with the engine harness electrical connectors to the right side fuel injectors before installing the engine harness clip onto the ignition coil bracket stud. Route the engine harness electrical connectors for left side fuel injectors and ignition coil harness electrical connector before placing the cpa retainer. The engine wiring harness electrical connector should be attached to both MAP Sensor and evap canister purge solenoid before the engine harness retainer can be installed with a nut torque of 5 nm (44 lb in). Complete the high voltage service connect after reinstalling the air cleaner outlet duct and reattaching the battery ground cable.

Remove the positive crankcase ventilation (PCV) hose and loosen the intake manifold bolts (512) before removing the intake manifold (500) and covering the cylinder head passages to prevent debris entry.

Connect the engine harness electrical connectors to the left side fuel injectors, the ignition coil harness, and install the CPA retainer.

Remove the engine harness clamp, oil pressure sensor connector, and engine wiring harness bracket bolt, then reposition the wiring harness.

Remove the engine harness clamp, oil pressure sensor connector, and engine wiring harness bracket bolt, then reposition the wiring harness.

Remove the PCV valve hose, the power brake booster vacuum hose, and the upper intake manifold - upper studs.

First, remove the air cleaner outlet duct.

Loosen and remove the intake manifold, discarding the gaskets, and cover the cylinder head passages to prevent debris entry.

Reattach the brake booster vacuum hose to the booster fitting, secure the engine harness, connect all previously disconnected electrical connectors, and finally install the generator and air cleaner outlet duct.