Intake Manifold Assembly (Unit Repair)

INTAKE MANIFOLD ASSEMBLY

Intake Manifold Tightening Sequence:

REMOVE OR DISCONNECT
1. Fuel rail covers.
2. Fuel rail bolts/screws.
3. Fuel pressure regulator vacuum tube assembly.
4. Fuel injectors and fuel rail assembly from intake manifold assembly.
5. Exhaust gas recirculation (EGR) vacuum harness assembly and crankcase vent hoses.
6. EGR control valve assembly and bracket.
7. Canister purge valve assembly and bracket.
8. Move wiring harness assemblies out of area.
9. Disconnect distributor wiring harness assembly, if necessary.
10. EGR valve nuts, valve assembly and gasket.
11. Right exhaust manifold air injection pipe bolts/ screws, pipe, gasket and check valve as an assembly from intake and exhaust manifold assemblies and cylinder head assembly.
12. Accelerator cable bracket bolt/screw and bracket.
13. Throttle body bolts/screws, throttle body assembly and gasket.
14. Intake manifold bolts/screws and studs.
15. Intake manifold assembly and gaskets.

CLEAN
^ Intake manifold bolts/screws and studs.
^ Cylinder head assembly, engine block and intake manifold sealing surfaces.

INSTALL OR CONNECT
1. Apply a 5 mm (3/16 inch) bead of RTV sealer, GM P/N 1052366 or equivalent, to front and rear of engine block. Extend bead 13 mm (1/2 inch) up each cylinder head assembly to seal and retain gaskets.
2. Intake manifold assembly with new gaskets.
3. Intake manifold bolts/screws and studs.

TIGHTEN
^ Intake manifold bolts/screws and studs in a first pass to 8 Nm (71 lb in) in sequence. Tighten in sequence in a second pass to final specifications of 48 Nm (35 ft lb).

4. Throttle body assembly, gasket and bolts screws.

TIGHTEN
^ Throttle body bolts/screws to 26 Nm (19 ft lb).

5. Accelerator cable bracket and bolts/screws.

TIGHTEN
^ Accelerator control cable bracket bolts/screws to 10 Nm (90 lb in).

6. EGR valve assembly and bolts/screws.
7. EGR control valve assembly and bracket bolts/ screws.

TIGHTEN
^ EGR valve bolts/screws to 22 Nm (16 ft lb).
^ EGR control valve nut to 22 Nm (16 ft lb).

8. Canister purge valve assembly and bracket nut.

TIGHTEN
^ Evaporative emission canister purge solenoid valve bracket nut to 20 Nm (15 ft lb).

9. EGR vacuum harness assembly and crankcase vent hoses.
10. Fuel injectors with fuel rail assembly to intake manifold assembly.
11. Fuel pressure regulator vacuum tube assembly.
12. Fuel rail bolts/screws.

TIGHTEN
^ Fuel injection fuel rail bolts/screws to 20 Nm (15 ft lb).

13. Wiring harness assemblies if moved or disconnected.