In order to replace the Intake Manifold, remove it, as a whole unit with the
Throttle Body, oil fill tube, and
Fuel Injectors. Remove the electrical connectors used on the manifold absolute pressure (MAP) sensor,
Knock Sensor, and the exhaust gas recirculation (EGR) valve if so equipped. Disconnect the Knock Sensor harness connector and put the electrical harness aside. If present, remove the egr pipe bolts from the Intake Manifold , cylinder head , and exhaust manifold as well as take out the egr pipe and gasket. Unplug the pcv hose,
MAP Sensor, and ignition control cable bracket. Unbolt the outlet tube bolts and the bracket. Remove the evap purge solenoid vent tube by detaching the evap end from the solenoid, and remove the quick connect fitting from the vapor pipe. Take off the evap purge solenoid bolt, solenoid, and isolator from out of the Intake Manifold, remove the Intake Manifold bolts, and the manifold. After that, remove the old Intake Manifold gaskets and clean the gasket surfaces of the egr pipe and exhaust manifold (if present). Install new Intake Manifold gaskets on the manifold, install the manifold and apply a 5mm (0.20 inch) band of threadlock gm p/n 12345382 (Canadian P/N 10953489) or equivalent to Intake Manifold bolts. Tighten the bolts stepwise to 5 nm (44 inch lbs) first and 10 nm (89 inch lbs) on the final turn. Replace the solenoid on the evap, the solenoid isolator, and the solenoid bolt. Tighten the solenoid bolt to 10 nm (89 inch lbs.). Mount the evap purge solenoid vent tube and the accelerator control cable bracket and its bolts, tighten with an 89 inch lbs. (10 Nm). Before installing the MAP Sensor and the pcv hose, apply clean engine oil on the MAP Sensor seal lightly. If provided, replace with a new egr pipe gasket onto the exhaust manifold and install egr pipe (with valve) bolt the egr pipe bolt to the specified torque values: the torque should be approximately 10 nm (89 inch lbs.) for Intake Manifold, 50 nm (37 ft. Lbs.) for the cylinder head, and 30 nm (22 ft. Lbs.) for the exhaust manifold. Return the electrical harness in position, reconnect the Knock Sensor harness, and the electric connectors of the MAP Sensor, knock sensor, and
EGR Valve in presence. Lastly, install the fuel injectors, oil fill tube and the Throttle Body.