Intake Manifold: Service and Repair

The content of this article/image reflects the changes identified in TSB

Bulletin No.: 06-06-01-008

Date: April 05, 2006

SERVICE MANUAL UPDATE

Subject:
Revised Intake Manifold Replacement

Models:
2006 Buick Rainier
2006 Chevrolet TrailBlazer Models
2006 GMC Envoy Models
2006 Saab 9-7X

with 4.2L Engine (VIN S - RPO LL8)



Intake Manifold Replacement


Removal Procedure

1. Relieve the fuel pressure.

2. Remove the throttle body.





3. Remove the powertrain control module (PCM) retaining bolts (3) and nuts (6).

4. Remove the PCM.

Note:
Refer to Fuel and Evaporative Emission/Hose/Pipe Connection Cleaning Notice.





5. Disconnect the fuel feed pipe (1) from the fuel rail. Refer to Quick Connect Fitting-Metal Collar.

6. Disconnect the integral clip (3) from the wire harness bracket.





7. Remove the engine wire harness bracket bolt.

8. Remove the electrical harness and vacuum lines from the intake manifold.





9. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.





10. Disconnect the crankcase ventilation hose from the intake manifold.





11. Disconnect the vacuum brake booster hose at the intake manifold.

12. Remove the generator. Refer to Generator Replacement.





Important:
The intake manifold bolts are captured within the intake manifold. Do not attempt to remove the bolts from the intake manifold.

13. Loosen the intake manifold bolts.

14. Remove the intake manifold.


Installation Procedure





1. Install a new intake manifold gasket to the intake manifold.

Note:
Refer to Fastener Notice

2. Install the intake manifold onto the engine and secure the manifold with the bolts.

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





3. Install the generator.

4. Install the vacuum brake booster hose to the intake manifold.





5. Lubricate the inner diameter of the crankcase ventilation hose.





6. Install the crankcase ventilation hose.

7. Connect the MAP sensor electrical connector.





8. Install the electrical harness and vacuum lines to the intake manifold.

9. Install the engine electrical harness bracket bolt.

Tighten the bolt to 10 N.m (89 lb in).





10. Connect the integral clip (3) to the wire harness bracket.

11. Connect the fuel feed pipe (1) to the fuel rail.





12. Install the PCM mounting studs (5) to the intake manifold.

Tighten the studs to 6 N.m (53 lb in).

13. Install the PCM (1) onto the studs (5).

14. Install the PCM retaining bolts (3).

Tighten the bolts to 8 N.m (71 lb in).

15. Install the PCM retaining nuts (6).

Tighten the nuts to 8 N.m (71 lb in).

16. Install the PCM harness connectors (2) to the PCM body.

17. Tighten the PCM harness connector retaining bolts (4).

Tighten the bolts to 8 N.m (71 lb in).

18. Install the throttle body.

19. Connect the negative battery cable.

20. Inspect for leaks using the following procedure:

20.1. Turn ON the ignition, with the engine OFF for 2 seconds.

20.2. Turn OFF the ignition, for 10 seconds.

20.3. Turn ON the ignition, with the engine OFF.

20.4. Inspect for fuel leaks.