Intake Manifold Replacement (Lower)
REMOVAL PROCEDURE1. Disconnect the negative battery cable.
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: Refer to Battery Disconnect Caution in Service Precautions.
2. Remove the upper intake manifold. Refer to Intake Manifold Replacement (Upper) in Unit Repair.
3. Drain the cooling system.
4. Remove the upper radiator hose.
5. Remove the generator.
6. Remove the drive belt tensioner. Refer to Drive Belt Tensioner 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 approved thread locking compound to the intake manifold bolt threads before assembly.
1. Install the lower intake manifold.
2. Install the lower intake manifold bolts.
^ Tighten the bolts in sequence to 15 Nm (11 ft. lbs.).
NOTICE: Refer to Fastener Notice in Service Precautions. Fastener Notice
3. Connect the negative battery cable.
4. Install the EGR valve outlet pipe.
5. Install the drive belt tensioner.
6. Install the generator.
7. Install the upper radiator hose.
8. Fill the cooling system.
9. Install the upper intake manifold.