Intake Manifold: Service and Repair

Intake Manifold Replacement

Removal Procedure
1. Relieve the fuel pressure.
2. Remove the throttle body.





3. Remove the powertrain control module (PCM) retaining bolts (3) and nuts (6).
4. Remove the PCM mounting studs (5) and position the PCM out of the way.





5. Disconnect the engine coolant temperature (ECT) sensor electrical connector (1).





6. Disconnect the fuel feed (1) and fuel return (2) pipes from the fuel rail.

Notice: Refer to Fuel and Evaporative Emission (EVAP) Hose/Pipe Connection Cleaning Notice in Service Precautions.

7. Disconnect the integral clip (3) from the wire harness bracket.





8. Remove the engine wire harness bracket bolt.
9. Position the engine electrical wire harness bracket with wires attached out of the way.





10. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.





11. Disconnect the crankcase ventilation hose from the intake manifold.





12. Disconnect the vacuum brake booster hose at the intake manifold.
13. Remove the generator.





14. Loosen the intake manifold bolts.

Important: The intake manifold bolts are captured within the intake manifold. Do not attempt to remove the bolts from the intake manifold.

15. Remove the intake manifold.

Installation Procedure
1. Install a new intake manifold gasket to the intake manifold.





2. Install the intake manifold onto the engine and secure the manifold with the bolts.
Tighten the intake manifold bolts to 10 Nm (89 inch lbs.).

Notice: Refer to Fastener Notice in Service Precautions.

3. Install the generator.





4. Install the vacuum brake booster hose to the intake manifold.





5. Lubricate the inner diameter of the crankcase ventilation hose with GM P/N 12345884 (Canadian P/N 5728223) or equivalent.
6. Install the crankcase ventilation hose.





7. Connect the MAP sensor electrical connector.
8. Properly position the engine electrical harness bracket to the intake manifold.





9. Install the engine electrical harness bracket bolt.
Tighten the bolt to 10 Nm (89 inch lbs.).





10. Connect the integral clip (3) to the wire harness bracket.
11. Connect the fuel feed (1) and fuel return (2) pipes to the fuel rail.





12. Connect the ECT sensor electrical connector (1).





13. Install the PCM mounting studs (5) to the intake manifold.
Tighten the studs to 6 Nm (53 inch lbs.).
14. Install the PCM (1) onto the studs (5).
15. Install the PCM retaining bolts (3).
Tighten the bolts to 8 Nm (71 inch lbs.).
16. Install the PCM retaining nuts (6).
Tighten the nuts to 8 Nm (71 inch lbs.).
17. Install the throttle body.
18. Connect the negative battery cable.
19. Inspect for leaks using the following procedure:
1. Turn ON the ignition, with the engine OFF for 2 seconds.
2. Turn OFF the ignition, for 10 seconds.
3. Turn ON the ignition, with the engine OFF.
4. Inspect for fuel leaks.