Intake Manifold: Service and Repair

Intake Manifold Replacement

Removal Procedure

Important: The intake manifold, throttle body, fuel rail, and injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.

1. Loosen the air cleaner outlet duct clamps at the following locations:
^ The throttle body
^ The mass airflow/intake air temperature (MAF/IAT) sensor
2. Remove the outlet duct bolt.
3. Remove the air cleaner outlet duct.





4. Relieve the fuel system pressure.
5. Disconnect the air conditioning (A/C) compressor pressure switch electrical connector (2).





6. Remove the harness clip from the cylinder head.





7. Disconnect the MAF/IAT sensor electrical connector.





8. Disconnect the following electrical connectors:
^ Main coil (1)
^ Electronic throttle control (ETC) (2)
^ Fuel Injectors (3)
9. Remove the harness clips from the fuel rail.





10. Disconnect the generator electrical connector.





11. Disconnect the following electrical connectors:
^ Evaporative emission (EVAP) purge solenoid (1)
^ Knock sensor (2)
^ Manifold absolute pressure (MAP) sensor (3)
^ Main coil (4)
^ Fuel Injectors (5)
12. Remove the harness clips from the fuel rail.
13. Remove the knock sensor harness electrical connector from the intake manifold.





14. Perform the following steps in order to disconnect the fuel injector electrical connector.
14.1. Mark the connectors to their corresponding injectors to ensure correct reassembly.
14.2. Pull the connector position assurance (CPA) retainer (2) on the connector up 1 click.
14.3. Push the tab (1) on the connector inch).
14.4. Disconnect the fuel injector electrical connector.
14.5. Repeat the steps for each injector electrical connector.





15. Remove the positive crankcase ventilation (PCV) hose (with valve).





16. Remove the heater water shutoff valve actuator inlet hose from the intake manifold.





17. Remove the evaporative emission (EVAP) purge solenoid vent tube by performing the following:
17.1. Remove the EVAP tube end from the solenoid.
17.2. Squeeze the EVAP pipe quick connect fitting retainer together.
17.3. Remove the EVAP tube end from the vapor pipe.





18. Remove the vacuum brake booster hose from the rear of the intake manifold.





19. Remove the upper engine wire harness retainer nut (1).
20. Reposition the upper engine wire harness aside.
21. Remove the intake manifold bolts.





22. Remove the intake manifold.





23. Remove the intake manifold gaskets (1) from the intake manifold.
24. Discard the old intake manifold gaskets.
25. If necessary, clean and inspect the intake manifold.

Installation Procedure





1. Install NEW intake manifold gaskets (1) to the intake manifold.





2. Install the intake manifold.
3. Apply a 5 mm (0.20 inch) bead of threadlock GM P/N 12345382, (Canadian P/N 10953489) or equivalent to the threads of the intake manifold bolts.

Notice: Refer to Fastener Notice in Service Precautions.





4. Install the intake manifold bolts.
4.1. Tighten the bolts a first pass in sequence to 5 Nm (44 inch lbs.).
4.2. Tighten the bolts a final pass in sequence to 10 Nm (89 inch lbs.).
5. Route the electrical harness into position over the engine.





6. Install the engine harness bracket nut (1).
^ Tighten the nut to 10 Nm (89 inch lbs.).





7. Install the vacuum brake booster hose to the rear of the intake manifold.





8. Install the EVAP purge solenoid vent tube.





9. Install the heater water shutoff valve actuator inlet hose to the intake manifold.





10. Install the PCV hose (with valve).





11. Connect the following electrical connectors:
^ EVAP purge solenoid (1)
^ Knock sensor (2)
^ (MAP sensor (3)
^ Main coil (4)
^ Fuel Injectors (5)
12. Install the harness clips to the fuel rail.
13. Install the knock sensor harness electrical connector to the intake manifold.





14. Perform the following steps in order to disconnect the fuel injector electrical connector.
14.1. Mark the connectors to their corresponding injectors to ensure correct reassembly.
14.2. Pull the connector position assurance (CPA) retainer (2) on the connector up 1 click.
14.3. Push the tab (1) on the connector inch).
14.4. Disconnect the fuel injector electrical connector.
14.5. Repeat the steps for each injector electrical connector.





15. Connect the generator electrical connector.





16. Connect the following electrical connectors:
^ Main coil (1)
^ ETC (2)
^ Fuel Injectors (3)
17. Install the harness clips to the fuel rail.





18. Connect the MAF/IAT sensor electrical connector.
19. Connect the A/C compressor pressure switch electrical connector (2).





20. Install the harness clip to the cylinder head.
21. Install the air cleaner outlet duct.
22. Install the outlet duct bolt.
^ Tighten the bolt to 10 Nm (89 inch lbs.).
23. Tighten the air cleaner outlet duct clamps at the following locations:
^ The throttle body
^ The MAF/IAT sensor
^ Tighten the clamps to 7 Nm (62 inch lbs.).
24. Install the fuel fill cap.
25. Connect the negative battery cable.





26. Use the following procedure in order to inspect for leaks:
26.1. Turn the ignition ON, wit the engine OFF, for 2 seconds.
26.2. Turn the ignition OFF for 10 seconds.
26.3. Turn the ignition ON, with the engine OFF.
26.4. Inspect for fuel leaks.