For 1990-2009 cars

## Intake Manifold Replacement Upper

### Removal Procedure

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Remove the fuel injector sight shield. Remove the air intake duct.
3. Disconnect the spark plug wires from the right side of the engine.
4. Remove the manifold vacuum source.
5. Depressurize the fuel lines.
6. Remove the fuel rail.
7. Remove the EGR heat shield.
8. Remove the cable bracket to the cylinder head mounting bolt.
9. Remove the throttle cable.
10. Remove the throttle body support bracket.
11. Remove the upper intake manifold.

### Installation Procedure

1. Install the upper intake manifold.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the upper intake manifold bolts.

Tighten
Tighten the upper intake bolts to 10 N·m (89 lb in).

3. Install the throttle body support bracket.
4. Install the throttle body cable.
5. Install the cable bracket to the cylinder head mounting bolt.
6. Install the EGR heat shield.
7. Install the fuel rail.
8. Install the manifold vacuum source.
9. Connect the spark plug wire to the right side of the engine.
10. Install the fuel injector sight shield. Install the air intake duct.
11. Connect the negative battery cable.

## Intake Manifold Replacement VIN 1

### Removal Procedure

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
3. Remove the front splash shield.
4. Drain the coolant. Refer to Drive Belt Replacement in Cooling.
5. Close the radiator drain cock. Install the front splash shield.
6. Lower the vehicle.
7. Remove the supercharger. Refer to Supercharger Replacement .
8. Remove the thermostat housing. Refer to Engine Coolant Thermostat Replacement in Engine Cooling.
9. Remove the EGR tube at the intake manifold.
10. Remove the electrical connection at the temperature sensor.
11. Remove the intake manifold.

### Installation Procedure

Important: In order to install the manifold, complete the following steps:

• | Use a suitable solvent in order to clean all oil from the cylinder block, the cylinder heads, and the intake manifold sealing surface.

• | Apply a GM approved sealer to the ends of the intake manifold seals.

• | Clean any adhesive compound from the intake manifold bolts and the bolt holes.

• | Apply a GM approved thread locking compound to the intake manifold bolts.

1. Install the intake manifold.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the intake manifold bolts.

Tighten
Tighten the intake manifold bolts in sequence to 15 N·m (11 lb ft).

3. Install the electrical connector at the temperature sensor.
4. Install the EGR tube to the intake manifold.
5. Install the thermostat housing. Refer to Engine Coolant Thermostat Replacement in Engine Cooling.
6. Install the supercharger. Refer to Supercharger.
7. Refill the coolant. Refer to Cooling System Draining and Filling in Cooling.
8. Connect the negative battery cable.

## Intake Manifold Replacement VIN K

### Removal Procedure

Important: Engine Code K has two bolts which are hidden beneath the upper intake. These bolts are located in the right front and left rear corners of the lower intake manifold. It is necessary to remove the upper intake manifold to service the lower intake.

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Remove the upper intake manifold. Refer to Intake Manifold Replacement .
3. Drain the cooling system. Refer to Cooling System Draining and Filling in Cooling.
4. Remove the upper radiator hose.
5. Remove the generator. Refer to Generator Replacement in Engine Electrical.
6. Remove the drive belt tensioner. Refer to Drive Belt Replacement .
7. Remove the EGR valve outlet pipe.
8. Remove the lower intake manifold bolts.
9. Remove the lower intake manifold.

### Installation Procedure

Important: In order to complete the installation, observe the following assembly tips:

• | Clean the cylinder block, heads and the intake manifold sealing surface of all oil with a suitable solvent.

• | Clean the intake manifold bolts and bolt holes of adhesive compound.

• | Apply GM P/N 12345493 threadlocker compound to the intake manifold bolt threads before assembly.

1. Install the lower intake manifold.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the lower intake manifold bolts.

Tighten
Tighten the lower intake bolts in sequence to 15 N·m (11 lb ft).

3. Connect the negative battery cable.
4. Install the EGR valve outlet pipe.
5. Install the drive belt tensioner. Refer to Drive Belt Replacement .
6. Install the generator. Refer to Generator Replacement in Engine Electrical.
7. Install the upper radiator hose.
8. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
9. Install the upper intake manifold. Refer to Intake Manifold Replacement .