Upper Intake Manifold Replacement

REMOVAL PROCEDURE





1. Disconnect the battery ground (negative) cable.
2. Carefully disconnect the throttle body air inlet duct.
3. Drain the engine coolant from the cooling system.
4. Remove the fuel injector sight shield.
5. Remove the right (rear) spark plug wires.
6. Disconnect the evaporative emissions canister purge solenoid valve wiring harness connector.
7. Relieve the fuel pressure.
8. Remove the fuel rail.
9. Remove the brake booster hose from the vacuum source manifold in the upper intake manifold.
10. Remove the EGR shield to the upper intake manifold.





11. Remove the throttle body support bracket.





12. Disconnect the MAP sensor electrical connector.
13. Remove the upper intake manifold bolts.
14. Clean the upper intake manifold bolt threads.
15. Remove the upper intake manifold.





16. Remove the upper-to-lower intake manifold carrier gasket from the upper intake manifold.
17. If the upper intake manifold is being replaced, remove the throttle body.





18. If the upper intake manifold is being replaced, remove the vacuum source manifold.


INSTALLATION PROCEDURE





1. If the upper intake manifold is being replaced, install the vacuum source manifold.
2. If the upper intake manifold is being replaced, install the throttle body.





3. Install the upper-to-lower intake manifold carrier gasket to the upper intake manifold.





4. Carefully place the upper intake manifold onto the lower intake manifold. Ensure that the alignment pins in the upper intake manifold align with the holes in the lower intake manifold.
5. Install the upper intake manifold.
6. Apply thread lock compound GM P/N 12345382 or equivalent, to the bolt threads before assembly.





Notice: Refer to Fastener Notice in Service Precautions.

7. Install the upper intake manifold bolts (1-10).
^ Tighten the upper intake manifold bolts in sequence to 10 Nm (89 inch lbs.).
8. Connect the MAP sensor electrical connector.





9. Install the throttle body support bracket.
10. Install the throttle body support bracket bolts.
^ Tighten the throttle body support bracket bolts to 10 Nm (89 inch lbs.).





11. Install the EGR shield to the upper intake manifold.
12. Install the brake booster hose to the vacuum source manifold in the upper intake manifold.
13. Install the fuel rail.
14. Connect the evaporative emissions canister purge solenoid valve wiring harness connector.
15. Install the right (rear) spark plug wires.
16. Install the fuel injector sight shield.
17. Refill the cooling system with engine coolant.
18. Carefully install the throttle body air inlet duct.
19. Connect the battery ground (negative) cable.
20. Inspect for the proper fluid levels.
21. Inspect for fluid or vacuum leaks.