Intake Manifold: Service and Repair

Throttle Cable Bracket To Throttle Body:

Throttle Body And Adapter To Intake Manifold:

Intake Manifold And Gaskets:

Intake Manifold Bolt Tightening Sequence:

REMOVE OR DISCONNECT
1. Release fuel pressure and disconnect fuel lines from fuel rail, refer to Fuel Delivery and Air Induction / Fuel Pressure Release.
2. Negative battery cable.
3. Drain coolant in suitable container.
4. Drive belt, alternator and brace.
5. Power steering pump braces.
6. Coolant bypass hose, heater pipe and upper radiator hose.
7. Air inlet duct and throttle cable bracket from throttle body.
8. Vacuum hoses and electrical connectors from intake manifold.
9. EGR pipe, EGR valve and adapter from throttle body adapter.
10. Throttle body coolant pipe from intake manifold.
11. Throttle body adapter and throttle body from intake manifold.
12. Rear spark plug wires.
13. Intake manifold bolts and intake manifold.
14. Clean the cylinder block, heads and intake manifold sealing surfaces of ALL oil with a suitable solvent.
15. Clean the intake manifold bolts and bolt holes of adhesive compound.

INSTALL OR CONNECT
1. Intake manifold gaskets and seals. Apply GM sealer P/N 12345336 or equivalent to the ends of the manifold seals.
2. Intake manifold.
3. Apply thread lock compound P/N 12345493 to the intake manifold bolt threads, install and tighten the bolts TWICE in sequence to 10 Nm (88 lbs in).
4. Rear spark plug wires.
5. Throttle body and adapter to intake manifold.
6. Lubricate throttle body coolant pipe seal with antifreeze and connect to intake manifold.
7. EGR adapter and valve to throttle body adapter, then the EGR pipe.
8. Vacuum hoses and electrical connectors to intake manifold.
9. Throttle cable bracket from throttle body and air inlet duct.
10 Upper radiator hose, heater pipe (lubricate heater pipe O-ring seal with antifreeze) and coolant bypass hose.
11. Power steering pump braces.
12. Alternator, brace and drive belt.
13. Connect fuel lines from fuel rail.
14. Fill cooling system.
15. Negative battery cable.