GM 19371505
Intake Manifold

To replace the Intake Manifold, first, switch the ignition off and then remove the fuel injector sight shield. Then remove the air outlet duct and unplug the Brake Booster Vacuum Hose, purge solenoid valve electrical connector, and purge line from purge solenoid valve. Remove the retainer and disconnect the throttle body electrical connector. Then gap the upper Intake Manifold brace stud , bolt , brace, disconnect the positive crankcase ventilation (PCV) hose from the right bank camshaft cover, the barometric pressure sensor electrical connector, and the Intake Manifold runner control solenoid electrical connector. Take out the bracket bolts that hold injector harness bracket, and we will also remove the left bank ignition coil wiring harness and should have no problems with that, then removing the upper Intake Manifold bolts, and there might be some deflection of the cowl panel that might be needed to pull the right rear bolt. Remove the upper Intake Manifold while it contains the throttle body and in the process of replacing disassemble the Intake Manifold, clean and inspect it. For installation, if necessary, assemble the Intake Manifold, put a new upper Intake Manifold gasket back in place, and then the upper Intake Manifold. Tighten the Intake Manifold mounts in a circular fashion from the middle (long bolts) and finish to 23 n.m (17 lb ft). Join the barometric pressure sensor electrical connector, Intake Manifold runner control solenoid electrical connector, and pcv hose to the right bank camshaft cover. Mount the upper Intake Manifold brace, stud, and bolt compressing the brace bolt to 65 n.m (48 lbft) and brace stud to 10 n.m (89 lb in). Make sure to properly engage the wiring harness connector and then attach the electrical connector to the throttle body, installing the wiring harness retainer, attaching the purge line to the purge solenoid valve, and the purge solenoid valve electrical connector. Lastly, attach the Brake Booster Vacuum Hose to the Intake Manifold, place the spare air outlet duct, and reinstall the fuel injector sight shield.

Disconnect the purge solenoid electrical connector.

Remove the intake manifold bolts (1-6) and take out the upper intake manifold, discarding the upper intake manifold gasket.

Install the fuel pressure and EVAP hoses to the engine and the air inlet duct.

Disconnect the purge solenoid electrical connector twice.

Install the fuel pressure and EVAP hoses to the engine and reattach the air inlet duct.

Disconnect the wiring harness connectors from the throttle position (TP) sensor and idle air control (IAC) valve.

If necessary, remove the fuel rail and then the intake manifold bolts to take off the intake manifold from the intake manifold flange, followed by removing the seals.

Install the upper intake manifold brace, bolt to 65 N.m (48 lb ft), and stud to 10 N.m (89 lb in), followed by the wiring harness retainer, ensuring proper engagement of the wiring harness connector.

Reinstall the power steering pump, fuel injector rail, and connect the fuel feed and return pipe along with its retaining clip and bolt.

Turn the ignition OFF and remove the fuel injector sight shield.

Remove the PCV line from the clip on the harness bracket, the left bank ignition coil wiring harness from the bracket, the injector harness bracket bolt and bracket, and the upper intake manifold bolts.

Remove the upper intake manifold brace stud, bolt, and brace.

Disconnect the purge solenoid valve electrical connector, the fuel injector harness electrical connector, and the throttle body electrical connector.

Assemble the intake manifold if it is being replaced, install a NEW upper intake manifold gasket, and then the upper intake manifold.

Reinstall the fuel line to the retainer at the rear of the right head and connect it to the fuel rail. Install the EVAP purge valve line to the retainer at the rear of the right head, followed by the EVAP purge valve line and electrical connector.

Proper engagement of the wiring harness connector.

Tighten the brace bolt to 65 Nm (48 ft. lbs.) and the brace stud to 10 Nm (89 inch lbs.).

Tighten the intake manifold bolts in a circular pattern starting at the center (long bolts) and moving outward to 23 Nm (17 ft. lbs.).

Note the booster hose routing.

Reconnect the barometric pressure sensor electrical connector, intake manifold runner control solenoid electrical connector, and PCV hose to the right bank camshaft cover.

Install the sight shield bracket and tighten the sight shield bracket nuts to 10 Nm (89 inch lbs.), then install the PCV fresh air tube, PCV dirty air tube, fuel injector sight shield, and cross car brace.

Remove it from the bracket, ensuring not to remove the upper to lower intake manifold bolts or damage the fuel pipe.

Remove the upper intake manifold and the heater inlet pipe.

Clean all lower intake manifold bolts and torque them in sequence: first to 13 Nm (115 lb in), then to 20 Nm (15 lb ft) for bolts (1, 2, 3, 4), and finally to 25 Nm (18 lb ft) for bolts (5, 6, 7, 8).

Reposition the vacuum brake booster hose clamp and remove the vacuum brake booster hose.

Remove the fuel injector inline connector clip.