To replace the Intake Manifold, first removes two nuts from the Intake Manifold sight shield and removes sight shield from the engine. Take off the module coil connectors from coil modules in camshaft covers, of the PCV Valve in the camshaft cover, pcv fresh air tube at the camshaft cover, fuel regulator vacuum tube, vacuum tubes on the air solenoid. Away from the fuel pre-infilt and return quickies at the
Fuel Rail, the attitude of the rear lift bracket nut of the Fuel Rail bracket, away from the two pushnuts securing engine cooling heater wire and so on (if equipped). It should be done by carefully moving the generator coolant pipe aside from the Fuel Rail studs, removing the eight electrical connectors from the eight
Fuel Injectors, and disconnecting the four bolts that hold the Fuel Rail to the Intake Manifold. Lift the total Fuel Rail and injection assembly from the Intake Manifold, lose the plenum duct clamp at the rear end of the Intake Manifold and lose the ten bolts connecting the Intake Manifold to the Cylinder Head. Remove the Intake Manifold using an upward lifting opposite the front of the manifold assembly, clean and inspect the manifold. Both the inside edge of the rubber plenum duct should be lightly greased and the Cylinder Head or Intake Manifold cleaned of any debris and both gaskets should be installed to the Intake Manifold and the PCV Valve hose should be fastened tightly to the fitting protruding at the front of the Intake Manifold before installation. Position the rear of the Intake Manifold into the plenum duct and lower the front of the Intake Manifold onto cylinders heads. Loosely fit the ten bolts to attach the Intake Manifold to the Cylinder Head and then the Intake Manifold bolts to be tightened in sequence to 10 nm (89 lb in). Make sure the plenum duct is firmly connected to the back side of the Intake Manifold and tighten the plenum duct clamp to 2.25 nm (20 lb in). Apply light mineral oil gm p/n9981704, clean engine oil or equally to lubricate the Intake Manifold Fuel Injector bores, and push all the Fuel Rail as well as all injectors simultaneously through the Intake Manifold into position. Torque the four bolts used to attach the Fuel Rail to the Intake Manifold to 10 nm (89 lb in). Attach the eight electrical connectors to the eight fuel injectors, and attach the cable harness clips to the cable harness at the front of the camshaft cover; then put the generator coolant pipe to the Fuel Rail studs, and attach the generator coolant pipe to the hoses. Mount the engine coolant heater wire onto the Fuel Rail studs and install the two pushnuts, then install the rear bracket retaining nut to the rear lift bracket and tighten to 4 nm (35 lb in). Mount the quick connect fittings to the Fuel Rail, attach the vacuum tubings to the air solenoid, the fuel regulator vacuum tubings, the pcv fresh air tubings to the camshaft cover, the PCV Valve to the camshaft cover, and the coil module connectors to the coil modules in the camshaft covers. In order to detect fuel leaks, switch the ignition switch on for 2 seconds and off for 10 seconds, followed by turning it on. Finally, fit the Intake Manifold sight shield to the engine and securely install the two Intake Manifold sight shield nuts with a torque of 3 nm (27 lb in).