Intake Manifold Replacement - Lower

Removal Procedure





1. Remove the engine cover from the vehicle. Refer to Engine Cover Replacement.
2. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
3. Disconnect the battery negative cable from the battery. Refer to Battery Negative Cable Disconnect/Connect Procedure.
4. Remove the upper intake manifold from the lower intake manifold. Refer to Intake Manifold Replacement (Upper Intake Manifold) or Intake Manifold Replacement (Lower Intake Manifold).
5. Remove the suction line from Air Conditioning from the A/C compressor. Refer to Compressor Hose Assembly Replacement in Heating and Air Conditioning.

Important: Mark the relationship of the distributor housing to the rotor for proper reinstallation.

6. Remove the distributor from the lower intake manifold. Refer to Distributor Replacement.
7. Remove the MAP sensor from the lower intake manifold.
8. Remove the radiator hose from the thermostat. Refer to Radiator Hose Replacement in Cooling System.
9. Remove the thermostat housing from the lower intake manifold from the engine block. Refer to Thermostat Replacement in Cooling System.
10. Remove the heater hoses from the heater core. Refer to Heater Hoses Replacement in Cooling System.
11. Remove the coolant bypass hose from the lower intake manifold and the water pump.
12. Remove the retaining bolts for the fuel rail. Refer to Fuel Hose/Pipes Replacement (Engine Compartment).
13. Remove the fuel rail from the lower intake manifold. Refer to Fuel Hose/Pipes Replacement (Engine Compartment).





14. Remove the lower intake manifold bolts from the engine head.
15. Remove the lower intake manifold from the cylinder head.
16. Remove the lower intake manifold gaskets and seals from the cylinder head.
17. Clean all sealing surfaces of oil and grease. Refer to Intake Manifold Clean and Inspect (Lower).


Installation Procedure





1. Install the lower intake manifold gaskets to the cylinder head with THIS SIDE UP stamped facing up.
2. Install the lower intake manifold to the engine block.
3. Apply the Loctite 242 GM P/N 12345382 to the lower intake manifold bolts.





Notice: Refer to Fastener Notice in Service Precautions.

4. Install the lower intake manifold bolts to the engine head.
^ Tighten the bolts in sequence to 30 Nm (22 ft. lbs.).
^ Re-tighten the bolts in sequence to 40 Nm (30 ft. lbs.).
5. Install the fuel rail to the lower intake manifold. Refer to Fuel Hose/Pipes Replacement (Engine Compartment).
6. Install the fuel rail retaining bolts. Refer to Fuel Hose/Pipes Replacement (Engine Compartment).
7. Install the coolant bypass hose to the water pump.
8. Install the heater hoses to the lower intake manifold. Refer to Heater Hoses Replacement in Cooling System.
9. Install the thermostat housing to the lower intake manifold from the engine block. Refer to Thermostat Replacement in Cooling System.





10. Install the MAP sensor to the lower intake manifold.
11. Install the radiator hose to the thermostat housing. Refer to Radiator Hose Replacement in Cooling System.
12. Install the distributor to the engine block. Refer to Distributor Replacement.
13. Install the suction hose to the A/C compressor. Refer to Compressor Hose Assembly Replacement in Heating and Air Conditioning.





14. Install the upper intake manifold to the lower intake manifold. Refer to Intake Manifold Replacement (Upper Intake Manifold) or Intake Manifold Replacement (Lower Intake Manifold).
15. Install the discharge line to the A/C compressor. Refer to Compressor Hose Assembly Replacement in Heating and Air Conditioning.
16. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
17. Connect the battery negative cable to the battery. Refer to Battery Negative Cable Disconnect/Connect Procedure.
18. Install Engine Cover. Refer to Engine Cover Replacement.