GM 91176128
Intake Manifold

In order to replace the Intake Manifold, disconnect the negative Battery Cable and reduce the fuel pressure and then drain the engine coolant. Disconnect the air cleaner hose, bolt and accelerator cable bracket from the Intake Manifold, and the cables from Throttle Body bellcrank. Disconnect besides the fuel injector harness, manifold absolute pressure (MAP) sensor, the throttle position (TP) sensor, idle air control (IAC) valve, evap canister purge valve, and exhaust gas recirculation (EGR) valve. Unbolt and ground all intake wires that are attached to the manifold, and the evap canister purge hose, the evap vacuum line, the bolt that supports the fuel line bracket, and take off the wiring harness from the retaining clamps. Upon removing the banjo fitting and washer from the rear end of Fuel Rail, the bolts that secure the fuel lines to the Fuel Rail, the front and top Intake Manifold support brackets, the nuts and bolts from the Intake Manifold, and lastly, the Intake Manifold accompanied by the part gasket. Examine the Intake Manifold for damages and clean the surfaces of the sealing gaskets. Replace the Throttle Body and the EGR Valve with the egr pipe and MAP Sensor to the new Intake Manifold, then add the new gasket on the cylinder head and attach the Intake Manifold with 9 nuts and 4 bolts that tighten down to 25 nm (19 ft. Lbs.). Replacement of the front and top support brackets using 2 bolts each, the fuel line bracket using 1 bolt, and fuel lines to the Fuel Rail using 2 bolts. Mount the washer and banjo fitting onto the Fuel Rail and bolt the fuel pressure regulator vacuum hose onto the Intake Manifold and tighten the coolant line using 2 bolts. Reattach the coolant hoses (4,5), install the evap canister purge valve by using 1 bolt and connect the canister purge hose, evap vacuum line, brake booster hose, pcv hose, and breather hose, to the Intake Manifold. Reconnect the electrical connectors for ground wires with the bolt, fuel injector harness, map sensor, tp sensor, iac valve, evap canister purge valve and EGR Valve and bind up the wiring-harness. Connect the Throttle Body bellcrank cables and attach the accelerator cable bracket with 1 bolt, adjust accelerator cable play if required, and the air cleaner hose. Lastly, install on the cooling system, turn on the engine and inspect for independent fuel and engine coolant leaks.

Remove the TWC bolts, both the upper front and rear intake manifold support brackets, the crankcase vent hose, the PCV hose from the PCV valve, and disconnect the fuel injector 6-way connector.

Remove the electrical harness clamps and detach the air intake hose from the throttle body.