Intake Manifold Replacement - Lower
Intake Manifold Replacement - LowerRemoval Procedure
1. Disconnect both the battery negative cables from the batteries.
2. Remove the upper intake manifold from the lower intake manifold.
3. Remove the fuel filter from the lower intake manifold and position to the side.
4. Remove the glow plug relay from the lower intake manifold.
5. Remove the nuts retaining the heater hose bracket.
6. Remove the heater hoses and bracket.
7. Remove the ground straps from the right rear corner of the lower intake manifold.
8. Disconnect the engine wiring harness (if needed) and secure out of the way.
9. Remove the lower intake manifold bolts from the cylinder head.
10. Remove the lower intake manifold and the gasket from the cylinder heads.
11. Clean and check the sealing surfaces of the cylinder head and the engine block.
Installation Procedure
1. Install the intake manifold and gaskets.
Notice: Refer to Fastener Notice in Service Precautions.
2. Install the intake manifold bolts/studs and fuel line clips.
^ Use Teflon sealer to seal the four bolts, numbers 9, 11, 13, and 15 that are exposed to the crankcase.
^ Apply threadlocker GM P/N 12345493 to the threads of the bolts and the studs that are not numbered 9, 11, 13, or 15.
Tighten the intake manifold bolts/studs, in sequence, to 42 Nm (31 ft. lbs.).
3. Install the grounds straps to the right rear of the cylinder head.
4. Install the ground strap nuts.
Tighten the ground strap nuts to 25 Nm (18 ft. lbs.).
5. Install the glow plug relay to the lower intake manifold.
6. Install the engine wiring harness (right side).
7. Install the heater hose bracket and nuts.
Tighten the heater hose bracket nuts to 30 Nm (522 ft. lbs.).
8. Install the fuel filter to the lower intake manifold.
9. Install the fuel filter bolts.
Tighten the fuel filter bolts to 42 Nm (31 ft. lbs.).
10. Install the upper intake manifold to the lower intake.
11. Connect both the battery negative cables to the batteries.