GM Service Manual Online
For 1990-2009 cars only

Removal Procedure

    Important: The intake manifold, throttle body, fuel rail, and injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.

  1. Remove the throttle body. Refer to Throttle Body Assembly Replacement in Engine Controls - 4.8L, 5.3L, and 6.0L.
  2. Remove the fuel injectors. Refer to Fuel Injector Replacement in Engine Controls - 4.8L, 5.3L, and 6.0L.

  3. Object Number: 679510  Size: SH
  4. Disconnect the following electrical connectors:
  5. • Manifold absolute pressure (MAP) sensor (1)
    • Knock sensor (2)
  6. Remove the knock sensor harness electrical connector from the intake manifold.
  7. Set the electrical harness aside.

  8. Object Number: 382483  Size: SH
  9. If equipped with vacuum assisted brakes, remove the vacuum brake booster hose from the rear of the intake manifold.

  10. Object Number: 647793  Size: SH
  11. Remove the positive crankcase ventilation (PCV) hose with valve.

  12. Object Number: 863068  Size: SH
  13. Remove the MAP sensor (1) from the intake manifold.

  14. Object Number: 832127  Size: SH
  15. Remove the evaporative emission (EVAP) purge solenoid vent tube by performing the following:
  16. 9.1. Remove the EVAP tube end from the solenoid (1).
    9.2. Remove the EVAP tube end from the vapor pipe (2).

    Object Number: 389993  Size: SH
  17. Remove the EVAP purge solenoid bolt (2), solenoid (3), and isolator (1) from the intake manifold.

  18. Object Number: 832132  Size: SH
  19. Loosen the intake manifold bolts.
  20. Remove the intake manifold.

  21. Object Number: 492770  Size: SH
  22. Remove the intake manifold gaskets (1) from the intake manifold.
  23. Discard the old intake manifold gaskets.
  24. If required, clean and inspect the intake manifold. Refer to Intake Manifold Cleaning and Inspection .

Installation Procedure


    Object Number: 492770  Size: SH
  1. Install NEW intake manifold gaskets (1) to the intake manifold.

  2. Object Number: 832132  Size: SH
  3. Install the intake manifold.
  4. Apply a 5 mm (0.20 in) band of threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent to the threads of the intake manifold bolts.

  5. Object Number: 63222  Size: SH

    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.

  6. Tighten the intake manifold bolts.
  7. Tighten

    1. Tighten the bolts a first pass in sequence to 5 N·m (44 lb in).
    2. Tighten the bolts a final pass in sequence to 10 N·m (89 lb in).

    Object Number: 389993  Size: SH
  8. Install the EVAP purge solenoid (3), isolator (1), and bolt (2) to the intake manifold.
  9. Tighten
    Tighten the bolt to 10 N·m (89 lb in).


    Object Number: 832127  Size: SH
  10. Install the EVAP purge solenoid vent tube to the solenoid (1) and vapor pipe (2).

  11. Object Number: 863068  Size: SH

    Important: Lightly coat the MAP sensor seal with clean engine oil before installing.

  12. Install the MAP sensor (1) to the intake manifold.

  13. Object Number: 647793  Size: SH
  14. Install the PCV hose with valve.

  15. Object Number: 382483  Size: SH
  16. If equipped with vacuum assisted brakes, install the vacuum brake booster hose to the rear of the intake manifold.
  17. Route the electrical harness into position over the engine.

  18. Object Number: 679510  Size: SH
  19. Connect the knock sensor harness electrical connector to the intake manifold.
  20. Connect the following electrical connectors.
  21. • MAP sensor (1)
    • Knock sensor (2)
  22. Install the fuel injectors. Refer to Fuel Injector Replacement in Engine Controls - 4.8L, 5.3L, and 6.0L.
  23. Install the throttle body. Refer to Throttle Body Assembly Replacement in Engine Controls - 4.8L, 5.3L, and 6.0L.