OEM 2004 Chevrolet Monte Carlo Intake Manifold

2004 Chevrolet Monte Carlo Parts Questions & Experts Answers

• Q: How to replace the upper intake manifold on 2004 Chevrolet Monte Carlo?

  A: Starting upper Intake Manifold replacement requires the removal of the negative Battery Cable connection. Pull out all vacuum hoses from the Fuel Pressure Regulator alongside the evaporative emissions (EVAP) canister purge valve and manifold vacuum source and Brake Booster and heater and air conditioning source. Start by unhooking electrical connectors from both the exhaust gas recirculation (EGR) valve and the mass air flow (MAF) sensor and intake air temperature (IAT) sensor and idle air control (IAC) valve and throttle position (T/P) sensor and evap canister purge valve. First drain the cooling system before removing the air cleaner intake duct. Detach the accelerator control and cruise control cables with bracket assembly from Throttle Body after taking the left Spark Plug Wires off the spark plugs. Disconnnect the camshaft position (CMP) sensor wiring harness, left side Spark Plug wire harness and engine wiring harness from their mount points. First disconnect the Throttle Body throttle bypass pipe coolant hoses (3, 4) before removing the ignition coil bracket and coils with the evap canister purge valve and MAP Sensor and bracket and EGR Valve. First unscrew the upper Intake Manifold bolts and stud before removing both the upper Intake Manifold together with its gaskets. The Throttle Body requires removal when you need to replace the upper Intake Manifold system but you should clean both upper intake gasket mating surfaces. The Throttle Body installation should precede gasket installation of the upper Intake Manifold and subsequent attachment of the upper Intake Manifold itself. Position the right upper Intake Manifold bolts and stud and tighten them to 25 nm (18 ft. Lbs.). Refit the EGR Valve and MAP Sensor bracket as well as sensor before installing the evap canister purge valve. First reattach the ignition coil bracket with its coils and then restore coolant hoses (3, 4) from the thermostat bypass pipe to the Throttle Body. Fasten the engine wiring harness and left side Spark Plug wire harness and camshaft position (CMP) sensor wiring harness into their retainers before installing the left side Spark Plug Wires to the spark plugs. After reconnecting the Throttle Body and accelerator control cables to the brake via their bracket the process ends by reattaching the air cleaner intake duct. Finally install electrical wiring to the evap canister purge valve along with Throttle Position Sensor (T/P), idle air control (IAC) valve, intake air temperature (IAT) sensor and mass air flow (MAF) sensor and EGR Valve. The installation procedure ends with connecting vacuum hoses to the heater and air conditioning source, brake booster, manifold vacuum source, evap canister purge valve and Fuel Pressure Regulator. Afterward, reattach the negative Battery Cable and complete the cooling system.