Upper Intake Manifold Replacement

Removal Procedure

Caution: Refer to Battery Disconnect Caution in Service Precautions.

1. Disconnect the negative battery cable.
2. Remove the top half of the air cleaner assembly.
3. Drain and recover the cooling system.
4. Remove the brake vacuum pipe at the plenum.
5. Disconnect the fuel pressure regulator vacuum hose (1) from the fuel pressure regulator (3) and the PCV valve (2).





6. Remove the spark plug wires.





7. Remove the electronic ignition coil and module assembly.





8. Remove the EVAP canister purge solenoid.





9. Disconnect the Throttle Position (TP) sensor.





10. Disconnect the IAC sensor.
11. Disconnect the Injector harness.





12. Disconnect the Engine Coolant Temperature (ECT) sensor.
13. Disconnect the Camshaft Position (CMP) sensor.
14. Disconnect the vacuum modulator.





15. Remove the MAP sensor vacuum line (3).
16. Disconnect the electrical connector.
17. Remove the bolts (2).
18. Remove the MAP sensor (1).





19. Remove the upper intake manifold bolts.





20. Remove the upper intake manifold and gaskets.
21. Clean the gasket surfaces.

Installation Procedure





1. Install the upper intake manifold gaskets on the manifold.

Notice: Refer to Fastener Notice in Service Precautions.

2. Apply thread lock GM P/N 12345382 to the threads of the bolts.
Install the upper intake manifold bolts.

^ Tighten the bolts to 25 Nm (18 ft. lbs.).





3. Install the bolts (2).
4. Install the MAP sensor vacuum line (3).
5. Connect the MAP sensor electrical connector.
6. Connect the vacuum modulator.





7. Install the vacuum hose (1) to the fuel pressure regulator (3) and the crankcase ventilation valve (2).





8. Connect the Throttle Position (TP): sensor.





9. Connect the IAC.
10. Connect the injector harness.
11. Connect the Engine Coolant Temperature (ECT) sensor.
12. Connect the Camshaft Position (CMP) sensor.





13. Install the EVAP canister purge solenoid.





14. Install the electronic ignition coil and module assembly.





15. Install the secondary ignition wires to the spark plugs.
16. Install the secondary ignition wires to the harness at the plenum.





17. Install the throttle body cable to the throttle body.





18. Install the cruise control cable to the throttle body.
19. Install the top half of the air cleaner assembly.
20. Install the brake vacuum pipe.
21. Fill the cooling system.
22. Connect the negative battery cable.
23. Inspect for proper fluid levels.
24. Inspect for leaks.