Intake Manifold Replacement

Intake Manifold Replacement

Removal Procedure

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

1. Remove the engine covers. Refer to Engine Cover Replacement Engine Cover Replacement.

2. Remove the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement (L99 or LS3) Air Cleaner Resonator and Outlet Duct ReplacementAir Cleaner Resonator and Outlet Duct Replacement (LSA) Air Cleaner Resonator and Outlet Duct Replacement.

3. Disconnect the electrical connector for the fuel injectors.

4. Disconnect the electrical connectors from the throttle body.

5. Disconnect the fuel feed for the fuel injectors. Refer to Fuel Line Replacement - Engine (L99 or LS3) Fuel Line Replacement - Engine.

6. Remove positive crankcase ventilation hose/pipe/tube. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (Dirty Air) Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (Dirty Air)Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (Clean Air) Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (Clean Air).





7. Remove the vacuum hose from the brake booster.

8. Disconnect the electrical connector from the manifold absolute pressure (MAP) sensor.





9. Remove the MAP sensor (714).

10. Remove the grommet (715) from the sensor, as required.





11. Remove the evaporative emission (EVAP) clip (740), bolt (742), bracket (741), valve (730) and tubes (729, 735).





12. Remove the intake manifold bolts (512) and the fuel rail stop bracket (712).

13. Remove the intake manifold (500).





14. Remove the intake manifold gaskets (514).

15. Discard the intake manifold gaskets.

16. If necessary clean and inspect intake manifold. Refer to Intake Manifold Cleaning and Inspection 72. Intake Manifold Cleaning and Inspection.

Installation Procedure





Note:
DO NOT reuse the intake manifold gaskets. Install NEW intake manifold gaskets.

Note:

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

* DO NOT use the intake manifold gaskets again. Install NEW intake manifold-to-cylinder head gaskets.

1. Install NEW intake manifold-to-cylinder head gaskets (514).





2. Install the intake manifold (500).

3. Apply a 5 mm (0.20 in) band of threadlocker to the threads of the intake manifold bolts (512). Refer to Adhesives, Fluids, Lubricants, and Sealers [1][2]Fluid Type Specifications.

4. Install the fuel rail stop bracket (712).

5. Install the intake manifold bolts (512).





Caution:
Refer to Fastener Caution Fastener Caution.

6. Tighten the intake manifold bolts to the sequence below:

* First Pass: Tighten the intake manifold bolts in sequence to 5 Nm (44 lb in).

* Second Pass: Tighten the intake manifold bolts in sequence to 10 Nm (89 lb in).





7. Lubricate the MAP sensor grommet (715) with clan engine oil.

8. Install the MAP sensor (714) and grommet (715).





9. Install the EVAP valve (730), bracket (741) and bolt (742).

Tighten the bolt to 50 Nm (37 lb ft).

10. Install the EVAP tubes (729, 735).

11. Install the fuel rail. Refer to Fuel Rail and Injectors Installation 108. Fuel Rail and Injectors Installation.

12. Connect the electrical connector for the MAP sensor.





13. Install the vacuum hose for the brake booster.

14. Connect the electrical connectors (3) for the throttle body.

15. Connect the electrical connector (1) for the fuel injectors.

16. Refill the cooling system. Refer to Cooling System Draining and Filling (GE 47716) Cooling System Draining and Filling (GE 47716)Cooling System Draining and Filling (LFX, Static Fill) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (LSA, LS3, L99 Static Fill) Cooling System Draining and Filling (Static Fill).

17. Install the engine covers. Refer to Engine Cover Replacement Engine Cover Replacement.