Hello, this is a 2 step process. There is an upper intake and lower. The first set is for the upper. the next post has the lower

Intake Manifold Replacement - Upper

Removal Procedure

1. Remove the fuel pipes/hoses.
2. Disconnect the cruise control cable from the throttle lever, if equipped.

1. Remove the cruise control cable from the accelerator control cable bracket, if equipped.

1. Remove the accelerator cable from the throttle body lever.

1. Remove the accelerator cable from the accelerator control cable bracket.

1. Disconnect the following electrical connectors:

• • The Air Conditioning (A/C) compressor clutch (1), if equipped
  • The A/C pressure switch (4), if equipped

1. Remove the engine wiring harness clip (3) from the accelerator control cable bracket.

1. Remove the accelerator control cable bracket nuts.
2. Remove the accelerator control cable bracket with the cables attached, from the throttle body.
3. Reposition and secure the bracket and cables out of the way.

1. Disconnect the following electrical connectors:

• • The Throttle Position (TP) sensor (1)
  • The Idle Air Control (IAC) motor (2)
  • The control port injector module (3)

1. Remove the engine wiring harness clip bolt (4).

1. Disconnect the following electrical connectors:

• • The Evaporative Emission (EVAP) canister purge solenoid valve (1)
  • The Manifold Absolute Pressure (MAP) sensor (2)

1. Disconnect the EVAP canister harness from the purge solenoid valve.

1. Remove the engine wiring harness bracket nuts.
2. Remove the engine wiring harness bracket.

1. Remove the engine wiring harness ground nut and ground wire (4) from the rear of the right cylinder head.

1. Remove the engine wiring harness rear bracket nut at the EVAP canister purge solenoid valve.
2. Remove the stud holding the engine wiring harness bracket.
3. Reposition the engine wiring harness with the bracket aside.

1. Remove the PCV valve hose from the valve and rocker cover.

1. Disconnect the power brake booster vacuum hose from the vacuum fitting.

1. Remove the accelerator cable bracket nuts.
2. Remove the accelerator cable bracket.

1. Remove the intake manifold - upper studs.
2. Remove the front two throttle body studs.
3. Remove the intake manifold - upper.

1. Remove and discard the intake manifold - upper gasket.

1. Remove and discard the O-ring seal from the fuel meter body.

1. If required, remove the power brake booster vacuum fitting.
2. Remove and discard the O-ring seal.

1. If required, remove the PCV valve cover.
2. Remove and discard the O-ring seal.

1. If required, remove the rear throttle body stud.
2. Remove the throttle body.
3. Remove and discard the throttle body gasket.

1. If required, remove the MAP sensor.
2. Remove and discard the MAP sensor seal.

1. If required, remove the EVAP canister purge solenoid valve studs.
2. Remove the purge solenoid valve.
3. Clean and inspect the intake manifold - upper, if necessary.

Intake Manifold Replacement - Lower

Removal Procedure

• The intake manifold may be removed as an assembly. Do not remove the specific intake manifold components unless component service is required.
• It is not necessary to remove the upper intake manifold in order to remove the lower intake manifold.
• Do not allow dirt or debris to enter the fuel system. Ensure that the ends of the fuel system are properly sealed.
• Do not disassemble the central sequential fuel injection (SFI) unit, unless service is required.

1. Drain the cooling system.
2. Remove the fuel pipes/hoses.
3. Remove the distributor.

1. Disconnect the Evaporative Emission (EVAP) canister harness from the purge solenoid valve.

1. Remove the heater hose clamp (1).

1. Open the heater outlet hose clamp and remove the hose from the intake manifold.

1. Open the heater inlet hose clamp and remove the hose from the water pump.
2. Reposition the heater inlet and outlet hoses.

1. Disconnect the cruise control cable from the throttle body lever, if equipped.
2. Remove the cruise control cable from the accelerator control cable bracket, if equipped.

1. Remove the accelerator cable from the throttle body lever.

1. Remove the accelerator cable from the accelerator control cable bracket.

1. Disconnect the following electrical connectors:

• • The Air Conditioning (A/C) compressor clutch (1), if equipped
  • The A/C pressure switch (4), if equipped

1. Remove the engine wiring harness clip (3) from the accelerator control cable bracket.

1. Remove the accelerator control cable bracket nuts.
2. Remove the accelerator control cable bracket with the cables attached, from the throttle body.
3. Reposition and secure the bracket and cables out of the way.

1. Disconnect the following electrical connectors:

• • The Throttle Position (TP) sensor (1)
  • The Idle Air Control (IAC) motor (2)
  • The control port injector module (3)

1. Remove the engine wiring harness clip bolt (4).

1. Disconnect the following electrical connectors:

• • The Evaporative Emission (EVAP) canister purge solenoid valve (1)
  • The Manifold Absolute Pressure (MAP) sensor (2)

1. Remove the engine wiring harness bracket nuts.
2. Remove the engine wiring harness bracket.

1. Remove the engine wiring harness ground nut and ground wire (4) from the rear of the right cylinder head.

1. Remove the engine wiring harness rear bracket nut at the EVAP canister purge solenoid valve.
2. Remove the stud holding the engine wiring harness bracket.
3. Reposition the engine wiring harness with the bracket aside.

1. Remove the PCV valve hose from the valve cover and rocker cover.

1. Disconnect the power brake booster vacuum hose from the vacuum fitting.

1. Reposition the radiator inlet hose clamps.
2. Remove the radiator inlet hose from the thermostat housing.

1. Reposition the water pump inlet hose clamps.
2. Remove the water pump inlet hose.

1. In order to remove the front intake manifold bolt, perform the following:

1. Remove the intake manifold - lower bolts.
2. Remove the intake manifold.
3. Remove and discard the intake manifold gaskets.
4. Clean and inspect the intake manifold - lower, if necessary.

Installation Procedure

1. Apply a 4.0 mm (0.157 inch) patch of adhesive GM P/N 12346141, (Canadian P/N 10953433), or equivalent to the cylinder head side of the intake manifold gasket at each end.

1. Install the intake manifold gasket onto the cylinder head. Use the gasket locating pins in order to properly seat the gasket.

1. Apply a 5 mm (0.197 inch) bead of adhesive GM P/N 12346141, (Canadian P/N 10953433), or equivalent to the front top of the engine block.
2. Extend the adhesive bead 13 mm (0.50 inch) up onto each intake manifold gasket.

1. Apply a 5 mm (0.197 inch) bead of adhesive GM P/N 12346141, (Canadian P/N 10953433), or equivalent to the rear top of the engine block.
2. Extend the adhesive bead 13 mm (0.50 inch) up onto each intake manifold gasket.

1. Install the intake manifold.
2. If reusing the old fasteners, apply threadlock GM P/N 12345382, (Canadian P/N 10953489), or equivalent to the threads of the intake manifold - lower bolts.
3. Install the intake manifold - lower bolts.

Intake Manifold Bolt Sequence

1. Tighten the intake manifold - lower bolts in the sequence shown.

1. Slide the P/S pump bracket rearward.
2. Install the bolts and the nut for the P/S pump bracket.
3. Install the P/S pump rear bracket front nut.
4. Tighten the P/S pump rear bracket nut. Tighten the bolts and nuts to 41 Nm (30 ft. lbs.).
5. Install the drive belt.

1. Install the water pump inlet hose.
2. Position the water pump inlet hose clamps.

1. Install the radiator inlet hose to the thermostat housing.
2. Position the radiator inlet hose clamps.

1. Connect the power brake booster vacuum hose to the vacuum fitting.

1. Install the PCV valve hose to the valve cover and rocker cover.

1. Position the engine wiring harness and bracket.
2. Install the engine wiring harness bracket stud.40 Tighten the stud to 25 Nm (18 ft. lbs.)
3. Install the engine wiring harness rear bracket nut at the EVAP canister purge solenoid valve. Tighten the nut to 9 Nm (80 inch lbs.).

1. Install the engine wiring harness ground nut and ground wire (4) to the rear of the right cylinder head. Tighten the nut to 16 Nm (12 ft. lbs.).

1. Install the engine wiring harness bracket.
2. Install the engine wiring harness bracket nuts. Tighten the nuts to 12 Nm (106 inch lbs.).

1. Connect the EVAP canister harness to the purge solenoid valve.