Intake Manifold: Service and Repair

Removal Procedure

Caution: Refer to Battery Disconnect Caution in Service Precautions.





1. Disconnect the negative battery cable.
2. Remove the air cleaner duct.
3. Disconnect the following electrical connectors: Manifold absolute pressure (MAP) sensor Intake air temperature (IAT) sensor Evaporative emissions (EVAP) canister purge solenoid Fuel injector harness
4. Disconnect the vacuum hoses from the fuel regulator and the EVAP canister purge solenoid to the canister.
5. Remove the accelerator control cable bracket.
6. Remove the stud-end generator mount bolt.





7. Remove the intake manifold retaining nuts and bolts.
8. Remove the intake manifold and the gasket.

Installation Procedure

Important: The engine and the manifold should be at ambient temperature when assembled. Do NOT attempt to install a cold manifold on a hot engine.





1. Install the intake manifold and the gasket. If damaged, install a new gasket with the stamped numbers facing towards the manifold surface.

Notice: Refer to Fastener Notice in Service Precautions.





2. Install the intake manifold fasteners in the sequence shown.
^ Tighten the fasteners to 24 Nm (18 ft. lbs.).
3. Install the EGR pipe to the EGR adapter fasteners.





4. Install the stud-end generator mount bolt.
5. Install the accelerator control cable bracket.
6. Connect the vacuum hoses to the fuel regulator and to the EVAP canister purge solenoid.

Important: If you have removed the intake air temperature (IAT) sensor, apply sealant GM P/N 1052080 or equivalent to the threads before installation.

7. Connect the following electrical connections:
^ MAP sensor
^ IAT sensor
^ EVAP canister purge solenoid
^ Fuel injector harness
8. Install the air cleaner duct.
9. Connect the negative battery cable.