GM Service Manual Online
For 1990-2009 cars only
Makes šŸ¢’ Pontiac šŸ¢’ 2005 šŸ¢’ Montana SV6 - AWD šŸ¢’ Engine šŸ¢’ Engine Electrical šŸ¢’ Upper Intake Manifold Replacement

Removal Procedure

    Object Number: 909586 Size: SH
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  2. Remove the vacuum hoses from the following:
    3. ā€¢ Evaporative emissions (EVAP) canister purge valve
    ā€¢ Brake booster
  3. Disconnect the electrical connectors from the following:
    4. ā€¢ Exhaust gas recirculation (EGR) valve
    ā€¢ Mass air flow (MAF) sensor
    ā€¢ Electronic throttle control
    ā€¢ EVAP canister purge valve
  4. Remove the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement .
  5. Drain the cooling system. Refer to Cooling System Draining and Filling .
  6. Remove the left side spark plug wires from the spark plugs. Refer to Spark Plug Wire Replacement .
  7. Remove the following wiring harnesses from the retainers:
    8. ā€¢ Camshaft position (CMP) sensor wiring harness
    ā€¢ Left side spark plug wire harness
    ā€¢ Engine wiring harness

    Object Number: 1239040 Size: SH
  8. Remove the ignition coil bracket with the coils. Refer to Ignition Control Module Replacement .
  9. Remove the EVAP canister purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement .
  10. Remove the manifold absolute pressure (MAP) sensor and the bracket. Refer to Manifold Absolute Pressure Sensor Replacement .
  11. Remove the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement .
  12. Remove the upper intake manifold bolts and the stud.
  13. Remove the generator bracket. Refer to Generator Bracket Replacement .
  14. Remove the upper intake manifold.
  15. Remove the upper intake manifold gaskets.

    16. Object Number: 1239002 Size: SH
  16. If replacing the upper intake manifold, remove the throttle body. Refer to Throttle Body Assembly Replacement .
  17. Clean the upper intake gasket mating surfaces.

Installation Procedure

    Object Number: 1239002 Size: SH
  1. If removed, install the throttle body. Refer to Throttle Body Assembly Replacement .

    2. Object Number: 1239040 Size: SH
  2. Install the upper intake manifold gaskets.
  3. Install the upper intake manifold.
  4. Apply threadlocker to the upper intake manifold bolt threads. Refer to Adhesives, Fluids, Lubricants, and Sealers for the 3.5L engine.

    5. Notice: Refer to Fastener Notice in the Preface section.

  5. Install the upper intake manifold bolts and the stud.

    6. Tighten
    Tighten the bolts and the stud to 25 NĀ·m (18 lb ft).

  6. Install the generator bracket. Refer to Generator Bracket Replacement .
  7. Install the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement .
  8. Install the MAP sensor bracket and the sensor. Refer to Manifold Absolute Pressure Sensor Replacement .
  9. Install the EVAP canister purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement .
  10. Install the ignition coil bracket with the coils. Refer to Ignition Control Module Replacement .
  11. Install the following wiring harnesses to the retainers:
    12. ā€¢ Engine wiring harness
    ā€¢ Left side spark plug wire harness
    ā€¢ CMP sensor wiring harness
  12. Install the left side spark plug wires to the spark plugs. Refer to Spark Plug Wire Replacement .
  13. Install the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement .
  14. Connect the electrical connectors to the following:
    15. ā€¢ EVAP canister purge valve
    ā€¢ Electronic throttle control
    ā€¢ MAF sensor
    ā€¢ EGR valve

    Object Number: 1239037 Size: SH
  15. Install the vacuum hoses to the following:
    16. ā€¢ Brake booster
    ā€¢ EVAP canister purge valve
  16. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  17. Fill the cooling system. Refer to Cooling System Draining and Filling .