Replacement (Lower)

This article has been updated with bulletin No.: 02-06-01-014

This article has been updated with bulletin No: 03-06-01-010B

LOWER INTAKE MANIFOLD

Fig. 4 Lower Intake Manifold & Gasket Removal:

REMOVE OR DISCONNECT
1. Remove upper intake manifold.

IMPORTANT: Relieve fuel pressure.

2. Fuel lines.
3. Fuel rail.
4. Wiring harness connectors.
5. Coolant hose.
6. Serpentine belt.
7. Generator bracket and braces.
8. Power steering pump.
9. Upper radiator hose.
10. Heater pipe.
11. Ignition coil bracket with:
a. Coils.
b. Purge solenoid.
c. Vacuum canister solenoid.

12. Engine mount strut.
13. Valve covers.
14. Lower intake bolts.
15. Lower intake.

CLEAN
- Gasket material from mating surfaces.
- Sealing surfaces with degreaser.

INSTALL OR CONNECT

IMPORTANT:
- All gasket mating surfaces need to be free of oil and foreign material. Use GM P/N 12346139 (in Canada, use GM P/N 10953463) or the equivalent to clean surfaces.





1. Install a new design intake manifold gasket. The material used in the gasket has been changed in order to improve the sealing qualities of the gasket. When replacing the gasket, the intake manifold bolts must also be replaced and torqued to a revised specification. The new bolts will come with a pre-applied threadlocker on them.





2. Apply small drops (8-10 mm [0.31-0.39 in]) of RTV sealer, GM P/N 12346286 (in Canada, use GM P/N 10953476) or the equivalent to the four corners of the intake manifold to block joint (1).
- Connect the small drops with a bead of RTV sealer that is between 8-10 mm (0.31-0.39 in) wide and 3.0-5.0 mm (0.12-0.20 in) thick (2).

3. Lower intake.
4. Apply sealant GM P/N 12345382 or equivalent to the threads of the bolts/screws.

NOTICE: An oil leak may result if the vertical bolts are not tightened before the diagonal bolts.

5. Hand tighten the vertical bolts/screws.
6. Hand tighten the diagonal bolts/screws.
7. Vertical bolts/screws.

NOTE: Diagonal bolts may require a crows foot to tighten.





8. Tighten intake manifold bolts

TIGHTEN
a. Tighten the vertical lower intake manifold bolts (1) to 7.0 Nm (62 lb. in.).
b. Tighten the diagonal lower intake manifold bolts (2) to 7.0 Nm (62 lb. in.).
c. Tighten the vertical lower intake manifold bolts (1) to 13.0 Nm (115 lb. in.).
d. Tighten the diagonal lower intake manifold bolts (2) to 25.0 Nm (18 lb. ft.).

9. Valve covers.
10. Engine mount strut.
11. Ignition coil bracket with:
a. Coils.
b. Purge solenoid.
c. Vacuum canister solenoid.

12. Ignition coil.
13. Heater pipe.
14. Upper radiator hose.
15. Power steering pump.
16. Generator bracket and braces.
17. Serpentine belt.
18. Coolant hose.
19. Wiring harness connectors.
20. Fuel rail.
21. Fuel lines.
22. Upper intake manifold.