Intake Manifold Replacement Lower VIN 1

1. Disconnect the battery ground (negative) cable. Refer to

   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.

   in General Information.
2. Drain the coolant. Refer to Engine Cooling.
3. Remove the supercharger. Refer to Supercharger Replacement .
4. Remove the thermostat housing. Refer to Engine Cooling.



5. Remove the EGR tube at the intake manifold.
6. Remove the electrical connection at the temperature sensor.



7. Remove the intake manifold. The coolant bypass tube will release from the intake manifold as the manifold is removed.
8. Remove the intake manifold gaskets.

Important: Before installing the manifold, complete the following steps:

1. Install the intake manifold gaskets.



2. Align the coolant bypass tube with the opening in the manifold. Install the intake manifold.
3. Install the intake manifold bolts.

Tighten
Tighten the intake manifold bolts in sequence to 15 N·m (11 lb ft).

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.

4. Install the electrical connector at the temperature sensor.



5. Install the EGR tube to the intake manifold.
6. Install the thermostat housing. Refer to Engine Cooling.
7. Install the supercharger. Refer to Supercharger Replacement .
8. Refill the coolant. Refer to Engine Cooling.
9. Connect the battery ground (negative) cable. Refer to Battery.

Intake Manifold Replacement Upper VIN K

Notice: The two bolts which fasten the lower intake manifold to the cylinder head are accessible only after the upper intake is removed. The bolts are located in the right front and left rear corners of the lower intake manifold. Remove the upper intake manifold to service the lower intake.

1. Disconnect the battery ground (negative) cable. Refer to

   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.

   .
2. Remove the air cleaner duct. Refer to Engine Controls.
3. Drain the engine coolant. Refer to Cooling and Radiator.
4. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
5. Remove the right (rear) spark plug wires. Refer to Ignition System.
6. Remove the canister purge solenoid electrical connector. Refer to Engine Controls.
7. Relieve the fuel pressure. Refer to Engine Controls.
8. Remove the fuel rail. Refer to Engine Controls.
9. Remove the brake booster hose from the upper intake manifold. Refer to Vacuum Booster System.
10. Remove the EGR shield to the upper intake manifold. Refer to Engine Controls.
11. Remove the throttle body. Refer to Engine Controls.



12. Remove the upper intake manifold bolts.
13. Remove the upper intake manifold.
14. Remove the upper-to-lower intake manifold seal.

1. Install the upper-to-lower intake manifold seal.
2. Carefully install the upper intake manifold onto the lower intake manifold.
3. Install the upper intake manifold.
4. Apply thread lock compound GM P/N 12345382 or equivalent, to the bolt threads before assembly.



5. Install the upper intake manifold bolts.

Tighten
Tighten the bolts in sequence to 10 N·m (89 lb in).

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.

6. Install the throttle body. Refer to Engine Controls.
7. Install the EGR shield to the upper intake manifold. Refer to Engine Controls.
8. Install the brake booster hose to the upper intake manifold. Refer to Vacuum Booster System.
9. Install the fuel rail. Refer to Engine Controls.
10. Install the canister purge solenoid electrical connector. Refer to Engine Controls.
11. Install the right (rear) spark plug wires. Refer to Ignition System.
12. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
13. Refill the cooling system with coolant. Refer to Cooling and Radiator.
14. Install the air cleaner duct. Refer to Engine Controls.
15. Connect the battery ground (negative) cable. Refer to Battery.
16. Inspect for the proper fluid levels.
17. Inspect for fluid or vacuum leaks.

Intake Manifold Replacement Lower VIN K

Notice: The two bolts which fasten the lower intake manifold to the cylinder head are accessible only after the upper intake is removed. The bolts are located in the right front and left rear corners of the lower intake manifold. Remove the upper intake manifold to service the lower intake.

1. Remove the upper intake manifold. Refer to Intake Manifold Replacement .
2. Remove the generator brace. Refer to Charging System.
3. Remove the generator. Refer to Charging System.
4. Remove the throttle body electrical connector. Refer to Engine Controls.
5. Remove the electrical connectors from both banks of the fuel injectors. Lay the electrical connectors aside. Refer to Engine Controls.
6. Remove the belt tensioner with mounting bracket. Refer to Drive Belt Tensioner Replacement .



7. Remove the coolant bypass from the intake.
8. Remove the upper radiator hose from the thermostat housing. Refer to Cooling and Radiator.
9. Remove the temperature sensor electrical harness connector.



10. Remove the lower intake manifold bolts.

Remove the lower intake manifold.




11. Remove the lower intake manifold gaskets and seals.
12. Inspect the flatness of inlet flanges.
13. Clean the engine block.
14. Clean the cylinder block, heads, and the intake manifold sealing surface with a suitable solvent.
15. Clean the intake manifold bolts and bolt holes of adhesive compound.

1. Apply sealer GM P/N 12345336 or equivalent to the ends of the intake manifold seals.
2. Install the lower intake manifold gaskets and seals.




Notice: The two bolts which fasten the lower intake manifold to the cylinder head are accessible only after the upper intake is removed. The bolts are located in the right front and left rear corners of the lower intake manifold. Remove the upper intake manifold to service the lower intake.

3. Install the lower intake manifold. Apply thread lock compound GM P/N 12345382 or equivalent to the two hidden bolts and ensure they are installed.



4. Install the intake manifold bolts.

Tighten
Tighten the intake manifold bolts in sequence to 15 N·m (11 lb ft).

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.

5. Install the temperature sensor electrical harness connector
6. Install the upper radiator hose to the thermostat housing. Refer to Cooling and Radiator.



7. Install the coolant bypass to the intake.
8. Install the drive belt tensioner mounting bracket. Refer to Drive Belt Tensioner Replacement .
9. Install the electrical connectors to both banks of the fuel injectors. Refer to Engine Controls.
10. Install the throttle body electrical connector. Refer to Engine Controls.
11. Install the generator. Refer to Charging System.
12. Install the generator brace. Refer to Charging System.
13. Install the upper intake manifold. Refer to Intake Manifold Replacement .