Intake Manifold Replacement - Lower

Intake Manifold Replacement (Lower)

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. For Vehicles equipped with OnStar (UE1) with Back Up Battery: The Back Up Battery is a redundant power supply to allow limited OnStar functionality in the event of a main vehicle battery power disruption to the VCIM (OnStar module). Do not disconnect the main vehicle battery or remove the OnStar fuse with the ignition key in any position other than OFF. Retained accessory power (RAP) should be allowed to time out or be disabled (simply opening the driver door should disable RAP) before disconnecting power. Disconnecting power to the OnStar module in any way while the ignition is On or with RAP activated may cause activation of the OnStar Back-Up Battery (BUB) system and will discharge and permanently damage the back-up battery. Once the Back-Up Battery is activated it will stay on until it has completely discharged. The BUB is not rechargeable and once activated the BUB must be replaced.

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.

1. Disconnect the negative battery cable.
2. Remove the upper intake manifold. Refer to Intake Manifold Replacement Upper Intake Manifold Replacement.
3. Drain the cooling system. Refer to Cooling System Draining and Filling Service and Repair.
4. Remove the upper radiator hose.
5. Remove the generator. Refer to Generator Replacement Service and Repair.
6. Remove the drive belt tensioner. Refer to Drive Belt Replacement Service and Repair.






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 thread locker 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 Nm (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 Service and Repair.
6. Install the generator. Refer to Generator Replacement Service and Repair.
7. Install the upper radiator hose.
8. Fill the cooling system. Refer to Cooling System Draining and Filling Service and Repair.
9. Install the upper intake manifold. Refer to Intake Manifold Replacement Upper Intake Manifold Replacement.