GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1996 🢒 Lumina APV 🢒 Engine 🢒 Engine Mechanical - 3.1L and 3.4L 🢒 Upper Intake Manifold Replacement

Removal Procedure
  1. Disconnect the negative battery 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 cooling system. Refer to Draining and Filling in Cooling and Radiator.

    3. Object Number: 61853 Size: MH
  3. Remove the air cleaner duct. Refer to Air Cleaner in Driveability and Emissions.
  4. Remove the acoustic engine cover.
  5. Remove the following from the throttle body:
    6. • The bracket with throttle control cables
    • The electrical connections
    • The coolant hoses
    • The vacuum hoses
  6. Remove the front spark plug wires. Refer to Front Spark Plug Wires in Ignition System.
  7. Loosen and reposition the ignition coil bracket with the coils, the purge solenoid and the vacuum canister.
  8. Remove the manifold air pressure sensor.
  9. Remove the brake booster hose. Refer to Brake Booster Hose in Vacuum Booster System.
  10. Remove the vacuum hoses from the upper intake.
  11. Remove the EGR valve.
  12. Remove the generator brace.
  13. Remove the upper intake manifold bolts.

    14. Object Number: 61854 Size: SH
  14. Remove the intake manifold with throttle body.
  15. Clean the gasket material from the mating surfaces.
  16. Clean the sealing surfaces with degreaser.

Installation Procedure

    Object Number: 54358 Size: SH
  1. Install the upper intake manifold gasket.
  2. Install the upper intake manifold with throttle body.
  3. Install the upper intake manifold bolts.

    4. Tighten
    Tighten the studs and bolts to 25 N·m (18 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 generator brace. Refer to Generator in Charging System.
  5. Install the EGR valve.
  6. Install all of the necessary vacuum hoses.
  7. Install the electrical connectors to the manifold.
  8. Install the vacuum hoses to the upper intake manifold.
  9. Install the power brake booster hose.
  10. Install the manifold air pressure sensor.
  11. Install the ignition coil with:
    12. • Coils
    • Purge solenoid
    • Vacuum canister solenoid
  12. Install the front spark plug wires.
  13. Install the following to the throttle body:
    14. • The bracket with throttle control cables
    • The electrical connections
    • The coolant hoses
    • The vacuum hoses
  14. Install the acoustic engine cover. Refer to Acoustic Engine Cover Replacement Acoustic Engine Cover Replacement
  15. Install the air cleaner and duct.
  16. Refill the cooling system. Refer to Draining and Filling in Cooling and Radiator.
  17. Connect the negative battery cable.