Upper Intake Manifold Replacement

Intake Manifold Replacement (Upper)

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.

1. Disconnect the negative battery cable.
2. Remove the fuel injector sight shield. Remove the air intake duct.
3. Disconnect the spark plug wires from the right side of the engine.
4. Remove the manifold vacuum source.
5. Depressurize the fuel lines.






6. Remove the fuel rail.
7. Remove the EGR heat shield.
8. Remove the cable bracket to the cylinder head mounting bolt.
9. Remove the throttle cable.






10. Remove the throttle body support bracket.
11. Remove the upper intake manifold.

Installation Procedure






1. Install the upper 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 upper intake manifold bolts.

Tighten
Tighten the upper intake bolts to 10 Nm (89 lb in).

3. Install the throttle body support bracket.
4. Install the throttle body cable.
5. Install the cable bracket to the cylinder head mounting bolt.
6. Install the EGR heat shield.






7. Install the fuel rail.
8. Install the manifold vacuum source.
9. Connect the spark plug wire to the right side of the engine.
10. Install the fuel injector sight shield. Install the air intake duct.
11. Connect the negative battery cable.