OEM 2003 Chevrolet Monte Carlo Intake Manifold

2003 Chevrolet Monte Carlo Parts Questions & Experts Answers

• Q: How to replace the lower intake manifold on 2003 Chevrolet Monte Carlo?

  A: The process starts by disconnecting the negative Battery Cable followed by removing the upper Intake Manifold alongside both left and right valve Rocker Arm covers and disconnecting the engine Coolant Temperature Sensor electrical connector. Disconnection of both the Fuel Injector wiring harness and manifold absolute pressure (MAP) sensor wiring harness is required before the removal of the fuel pipe clip bolt and fuel pipe clip. Start by removing the injector rail and relocate the Power Steering Pump along with extracting the heater inlet pipe with heater hose from the lower Intake Manifold. Disconnect the radiator inlet hose followed by separating the thermostat bypass hose from the thermostat bypass pipe and lower Intake Manifold pipe and remove all lower Intake Manifold bolts before discarding them. You should remove the lower Intake Manifold together with valve rocker arms and pushrods and lower Intake Manifold gaskets and seals. Thoroughly clean the mating surfaces of the lower Intake Manifold gaskets while removing all rtv sealant from both the lower Intake Manifold and engine block. The technician must first remove the ect sensor followed by the water outlet bolts and water outlet before proceeding to remove the thermostat. Begin by installing the thermostat and water outlet before tightening water outlet bolts to 25 nm (18 ft. Lbs). Incorporate gm p/n 12346139 (Canadian P/N 10953463) to clean gasket-mating surfaces and install the ect sensor. Apply an 8-10 mm (0.39-0.39 inch) bead of rtv sealer, gm p/n 12346141 (Canadian P/N 89022195) across the four corners of the Intake Manifold to create a block joint seal. Start by setting torque on center bolts then torque diagonal bolts for optimal lower Intake Manifold sealability. Apply the crows foot tool to tighten lower Intake Manifold bolts at positions 6 and 7 with specified torque values. Install the lower Intake Manifold and new lower Intake Manifold bolts, following a 2-step torque process: first tighten vertical bolts to 7 nm (62 lb in) then diagonal bolts to 7 nm (62 lb in) before ending with vertical bolt torques of 13 nm (115 lb in) and diagonal bolts at 25 nm (18 lb ft). Reattach the thermostat bypass hose with the radiator inlet hose and heater inlet pipe to the lower Intake Manifold securing the heater inlet pipe nut to 25 nm while tightening it to 18 foot pounds. Install the injector rail assembly afterward without touching the fuel pressure regulator valve then tighten injector rail bolts to 10 nm (89 in. Lbs). Fasten the fuel feed and return pipes with their retaining clip and bolt to 8 nm (71 in. Lbs), and then connect the Fuel Injector and MAP Sensor wiring harnesses and the ect sensor electrical connector. To finish the repair install first the right and left valve Rocker Arm covers then the upper Intake Manifold before reconnecting the negative Battery Cable and performing leak inspections.