Begin upper Intake Manifold replacement by removing the fuel injector sight shield then disconnecting the Brake Booster Vacuum Hose and releasing the clamp before separating the hose from the Intake Manifold. Disconnect the left side
Spark Plug Wires from their retainers and
Spark Plugs before you remove the Ignition Control Module bracket while keeping Ignition Control Module and wires connected. Position the bracket away from the work area. Maintain heat while disconnecting the heater outlet pipe from the
Throttle Body. Remove the lower nut from the upper Intake Manifold followed by both upper nuts and bolt from the Throttle Body until positioning the heater outlet pipe in place where heater hoses stay connected. Extract both the exhaust gas recirculation (EGR) tube and the positive crankcase ventilation (PCV) foul air tubing. Without completely removing the generator attachment bolt near the Intake Manifold start loosening it then remove the generator brace nut and brace. The maintenance procedure requires removal of upper Intake Manifold bolts (4, 5) and Spark Plug wire retainer and upper Intake Manifold together with upper Intake Manifold gaskets . To replace the upper Intake Manifold you must also dismantle the manifold absolute pressure (MAP) sensor alongside the
EGR Valve and evaporative emissions (EVAP) purge solenoid valve and Throttle Body and the fuel injector sight shield studs. During installation clamp upper Intake Manifold gaskets securely onto the lower Intake Manifold using fir tree retainers before mounting the upper Intake Manifold together with the Spark Plug wire retainer . Apply threadlock gm p/n 12345382 (Canadian P/N 10953489) to each upper Intake Manifold bolt thread before tightening the bolts (4, 5) to 25 nm (18 ft. Lbs.). The fuel injector sight shield studs need installation followed by the Throttle Body and evap purge solenoid valve, egr valve and
MAP Sensor. After applying threadlocker gm p/n12345382 (Canadian P/N10953489) to bolts, install the generator brace and tighten the generator brace nut to 25 nm (18 ft. Lbs.). Fully insert and tighten the generator attachment bolt nearest to the Intake Manifold to 25 nm (18 ft. Lbs.). Secure the pcv foul air hose together with the egr pipe while positioning the heater outlet pipe to fit both Throttle Body and upper Intake Manifold. Install both heater outlet pipe nuts onto the Throttle Body and tighten them to 10 nm (89 inch lbs.), followed by installing the heater outlet pipe bolt to the Throttle Body with a torque of 10 nm (89 inch lbs.) to attach the upper Intake Manifold nut tightly to 25 nm (18 ft. Lbs.). The repair process includes installing the air cleaner intake duct followed by the Ignition Control Module bracket, left side Spark Plug wire connection to spark plugs and respective retainers and Brake Booster Vacuum Hose connection to the Intake Manifold. Clamp installation should occur before reinstallation of the fuel injector sight shield.