For 1990-2009 cars

### Removal Procedure

1. Disconnect the negative battery cable. Refer to

   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.

   in General Information.
2. Drain the coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
3. Remove the throttle body air duct.
4. Remove the wiring harness connectors from the fuel injectors.
5. Remove the left and the right wiring harnesses and lay aside.
6. Remove the accelerator cable clips.
7. Remove the accelerator bracket and the accelerator cables from the throttle body.
8. Remove the accelerator control/cruise control servo cable adjuster.
9. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure in Engine Controls.
10. Remove the secondary air injection diverter valve hoses.
11. Remove the fuel pipe connectors from the fuel rail.
12. Remove the fuel rail bolts.
13. Remove the fuel pressure regulator vacuum tube.
14. Remove the fuel rail from the intake manifold and lay aside.
15. Remove the EGR valve vacuum harness.
16. Remove the crankcase vent hose.
17. Remove the exhaust gas recirculation (EGR) control valve relay nut and control valve relay.
18. Remove the emission canister purge solenoid bracket nut and the solenoid.
19. Remove the EGR valve nuts and the valve.
20. Remove the EGR valve pipe nuts and the studs.
21. Remove the secondary air injection pipe from the intake manifold and the right exhaust manifold.
22. Remove the generator rear brace. Refer to Generator Rear Brace in Engine Electrical.
23. Remove the coolant hoses from the throttle body.
24. Remove the following parts:

• | The throttle body bolts

• | The throttle body

• | The throttle body gasket

25. Remove the intake manifold bolts and studs.
26. Remove the intake manifold and the gaskets.
27. Discard the intake manifold gaskets.
28. Clean the following parts:

• | The intake manifold bolts and the studs

• | The cylinder head

• | The engine block

• | The intake manifold sealing surfaces

### Installation Procedure

1. Apply a 5 mm (0.189 in) bead of RTV sealer, GM P/N 12346192 or the equivalent, to the front of the engine block. Extend the bead 13 mm (0.5 in) up each cylinder in order to the seal and retain the gaskets.
2. Apply a 5 mm (0.189 in) bead of RTV sealer, GM P/N 12346192 or the equivalent, to the rear of the engine block. Extend the bead 13 mm (0.5 in) up each cylinder in order to the seal and retain the gaskets.
3. Install the intake manifold with the new gaskets.
4. Install the intake manifold bolts and the studs.

Tighten

• | Tighten the intake manifold bolts and the studs in a first pass to 10 N·m (89 lb in) in sequence.

• | Tighten the intake manifold bolts and studs in the second pass to the final specifications of 50 N·m (37 lb ft) in sequence.

5. Install the throttle body, gasket, and bolts.

Tighten
Tighten the throttle body bolts to 25 N·m (18 lb ft).

6. Install the coolant hoses to the throttle body.
7. Install the generator rear brace. Refer to Generator Rear Brace in Engine Electrical.
8. Install the accelerator control/cruise control servo cable adjuster.
9. Install the accelerator cable bracket, bolts, and cables.

Tighten
Tighten the accelerator cable bracket bolts to 12 N·m (106 lb in).

10. Install the secondary air injection pipe and the nuts.

Tighten
Tighten the secondary air injection pipe exhaust manifold fitting to 55 N·m (41 lb ft).

11. Install the EGR valve pipe studs and the nuts.
12. Install the EGR valve and the nuts.

Tighten

• | Tighten the EGR valve pipe studs to 6 N·m (53 lb in).

• | Tighten the EGR valve pipe nuts to 25 N·m (18 lb ft).

• | Tighten the EGR valve nuts to 25 N·m (18 lb ft).

• | Tighten the EGR Pipe to exhaust manifold bolt to 30 N·m (22 lb ft).

13. Install the EGR control valve relay and the nut.

Tighten
Tighten the EGR control valve relay nut to 25 N·m (18 lb ft).

14. Install the emission canister purge solenoid and the bracket bolt.

Tighten
Tighten the emission canister purge solenoid bracket bolt to 6 N·m (53 lb in)

15. Install the fuel rail to the intake manifold.
16. Install the fuel pressure regulator vacuum tube.
17. Install the fuel rail bolts.

Tighten
Tighten the fuel rail bolts to 10 N·m (89 lb in).

18. Install the fuel pipe connectors to the fuel rail.
19. Install the secondary air injection diverter valve hoses.
20. Install the left and the right wiring harnesses.
21. Install the wiring harness connectors to the fuel injectors.
22. Install the throttle body air duct.
23. Install the negative battery cable.
24. Refill with coolant. Refer to Cooling System Draining and Filling in Engine Cooling.