Alero, Grand Am 1999-2005

Intake Manifold

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Removal & Installation



These vehicles were filled at the factory with an antifreeze/coolant called GM Goodwrench DEX-COOL®. When adding coolant to vehicles, it is important that you use GM Goodwrench DEX-COOL (orange-colored, silicate-free) coolant. Propylene glycol is not recommended for use in GM vehicles . A 50/50 mixture of DEX-COOL and clean water will provide all the recommended protection. DO NOT mix DEX-COOL with any other type of antifreeze .

2.2L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Air inlet duct and resonator
     
    Idle Air Control (IAC) electrical connector
     
    Throttle Position (TP) sensor electrical connector
     
    Manifold Absolute Pressure (MAP) sensor electrical connector
     
    Evaporative Emissions (EVAP) hose
     
    Positive Crankcase Ventilation (PCV) hose
     
    Purge solenoid tube
     
    Brake booster hose
     
    Oil level indicator tube bolt
     
    Accelerator and cruise control cables
     
    Throttle body
     
    Fuel rail
     
    Knock Sensor (KS) connector from the intake manifold
     
    Intake manifold nuts and bolts
     
    Intake manifold and gasket. The gasket is reusable if the gasket is not damaged.

    Click image to see an enlarged view

    Fig. Remove the throttle body-2.2L engine



    Click image to see an enlarged view

    Fig. Remove the intake manifold-2.2L engine

     

  4.  

To install:

  1. Install or connect the following:

    Intake manifold gasket
     
    Intake manifold
     
    Intake manifold nuts and bolts and tighten to 89 inch lbs. (10 Nm)
     
    KS connector
     
    Fuel rail
     
    Throttle body
     
    IAC, TP, and MAP electrical connectors
     
    EVAP hose
     
    PCV hose
     
    Purge solenoid tube
     
    Brake booster hose
     
    Oil level indicator tube bolt
     
    Accelerator and the cruise control cables
     
    Air inlet duct and resonator
     

  2.  

3.1L & 3.4L Engines
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:
    NOTE
    When removing the valvetrain components, keep them in order for installation purposes.



    Air cleaner assembly
     
    Accessory drive belt
     
    Exhaust Gas Recirculation (EGR) valve
     
    Brake vacuum pipe at the intake plenum
     
    Fuel pressure regulator vacuum line
     
    Spark plug wires from the spark plugs and the intake plenum retainers
     
    Ignition coil assembly and the Evaporative Emissions (EVAP) canister purge solenoid as an assembly
     
    Throttle Position Sensor (TPS) electrical connector
     
    Idle Air Control (IAC) sensor electrical connector
     
    Fuel injector electrical connectors
     
    Engine Coolant Temperature (ECT) sensor electrical connector
     
    Camshaft Position (CMP) sensor electrical connector
     
    Vacuum modulator
     
    Manifold Absolute Pressure (MAP) sensor
     
    Coolant hoses from the throttle body
     
    Control cables from the throttle body and intake plenum bracket
     
    Upper intake plenum
     
    Both rocker arm covers
     
    Fuel lines from the fuel rail and fuel line bracket
     
    Fuel rail with the injectors
     
    Inlet cooling pipe from the outlet housing
     
    Heater bypass hose from the water pump and the cylinder head
     
    Upper radiator hose at the thermostat housing
     
    Thermostat housing
     
    Lower intake manifold
     



    Rocker arms and pushrods
     

  8.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the upper and lower intake-3.1L & 3.4L engines



Click image to see an enlarged view

Fig. Lower intake manifold tightening sequence-3.1L & 3.4L engines

  1. Place a 3mm bead of RTV, on each ridge, where the front and rear of the intake manifold contact the block.
  2.  
  3. Install or connect the following:
    WARNING
    In order to prevent oil leaks at the intake manifold, tighten the vertical bolts before the diagonal bolts.



    New intake manifold gasket
     
    Pushrods and rocker arms. Torque the bolts to 89 inch lbs. (10 Nm) plus an additional 30 degree turn.
     
    Lower intake manifold. Apply sealant to the threads of the bolts and torque the bolts to 115 inch lbs. (13 Nm).
     



    Thermostat housing with a new gasket. Torque the bolts to 19 ft. lbs. (26 Nm).
     
    Upper radiator hose at thermostat housing
     
    Coolant bypass hose to the water pump and the cylinder head
     
    Coolant inlet pipe to coolant outlet housing
     
    Fuel rail with the injectors
     
    Fuel lines to the fuel rail and fuel line bracket
     
    Both rocker arm covers. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Upper intake manifold with a new gasket. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Coolant hoses to the throttle body
     
    MAP sensor
     
    Vacuum modulator
     
    CMP sensor electrical connector
     
    ECT sensor electrical connector
     
    Fuel injector electrical connectors
     
    IAC sensor electrical connector
     
    TPS electrical connector
     
    Ignition coil assembly and the EVAP canister purge solenoid as an assembly
     
    Spark plug wires
     
    Fuel pressure regulator vacuum line
     
    EGR valve. Torque the bolts to 22 ft. lbs. (30 Nm).
     
    Control cables to the throttle body and intake plenum bracket
     
    Brake vacuum pipe at the intake plenum
     
    Accessory drive belt
     
    Air cleaner assembly
     
    Negative battery cable
     

  4.  
  5. Refill the cooling system.
    NOTE
    An engine oil and filter change is recommended.

  6.  
  7. Start the vehicle and verify no leaks.
  8.  

 
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