Aztek, Rendezvous 2001-2005

Intake Manifold

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Removal & Installation



3.4L Engine
Lower Manifold

This engine uses a 2-piece intake manifold. The upper half (often called a plenum) mounts the throttle body. The lower half of the manifold bolts to the engine and contains the fuel injectors. Please note that this engine uses a sequential multi-port fuel injection system. Injector connectors must be connected to their appropriate fuel injector assembly or engine emissions and engine performance will be seriously affected. Identify and tag for identification all wiring connectors as well as vacuum and other components as required to assure correct assembly.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Relieve the fuel system pressure using the recommended procedure.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Do not disconnect the power steering pipes or hoses from the steering pump.



    Negative battery cable
     
    Upper intake manifold
     
    Left and right side valve covers
     
    Wire harness from the Engine Coolant Temperature (ECT) sensor
     
    Fuel injector, Manifold Absolute Pressure (MAP) and ECT wire harness
     
    Fuel feed and return pipe from the injector rail

    Click image to see an enlarged view

    Fig. Remove the fuel injector rail-2002-03 3.4L engine

     



    Fuel injector rail
     
    Power steering pump from the front cover
     



    Heater inlet pipe with the heater hose from the lower intake manifold
     
    Radiator inlet hose
     
    Thermostat bypass hose from the manifold
     
    Lower intake manifold

    Click image to see an enlarged view

    Fig. Lower intake manifold assembly-2002-03 3.4L engine

     



    Pushrods after loosening the rocker arms
     
    Lower intake manifold gasket and seals
     
    ECT sensor, if replacing the manifold
     
    Thermostat and housing, if replacing the manifold
     

  8.  

To install:

  1. Clean the gasket mounting surfaces.
  2.  
  3. Inspect the intake manifold for cracks or damage, replace if necessary.
  4.  
  5. Install or connect the following:

    ECT sensor, if removed. Torque the sensor to 17 ft. lbs. (23 Nm).
     
    Thermostat and housing, if removed. Torque the fastener to 18 ft. Lbs. (25 Nm).
     
    Thin bead of RTV sealer (such as GM 12345739) on the ridge of the engine block where the lower intake manifold makes contact
     
    Lower intake manifold gaskets
     
    Pushrods and tighten the rocker arms. Torque the arms to 14 ft. lbs. (19 Nm) plus 30 degrees.
     
    Lower intake manifold. Torque the bolts to first to 62 inch lbs. (7 Nm) then to 115 inch lbs. (13 Nm) after applying a sealant (such as GM 12345382) to the threads of the bolts.
     
    Thermostat bypass hose to the lower intake manifold pipe. Torque the fastener to 18 ft. lbs. (25 Nm).
     
    Radiator inlet hose from the engine
     
    Power steering pump to the front cover
     
    Fuel injector rail. Torque the fastener to 89 inch lbs. (10 Nm).
     
    Fuel feed and return pipes to the injector rail. Torque the fasteners to 13 ft. lbs. (17 Nm).
     
    Wire harness for the fuel injector, MAP sensor and the ECT sensor
     
    Right side rocker arm cover. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Left side rocker arm cover. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Upper intake manifold. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Negative battery cable
     

  6.  
  7. Fill the coolant system.
  8.  
  9. Turn the ignition to the ON position several times to pressurize the fuel system.
  10.  
  11. Start the engine and check for any leakage and repair if necessary.
  12.  
  13. Check and top off all fluid levels if needed.
  14.  

  1. Remove the upper intake manifold.
  2.  
  3. Remove the engine left side valve rocker arm cover.
  4.  
  5. Remove the engine right side valve rocker arm cover.
  6.  
  7. Disconnect the wiring harness from the engine coolant temperature (ECT) sensor.
    NOTE
    Use masking tape or another appropriate method in order to identify each fuel injector wiring harness connector cylinder number.

  8.  
  9. Disconnect and remove the fuel injector, manifold air pressure (MAP) and ECT wiring harness.
  10.  
  11. Remove the fuel feed and return pipe from the fuel injector rail.
  12.  
  13. Remove the fuel feed and return pipe retaining clip bolt.
  14.  
  15. Remove the fuel feed and return pipe retaining clip.
  16.  
  17. Remove the fuel injector rail bolts.
  18.  
  19. Remove the fuel injector rail with the fuel injectors.
    NOTE
    Do NOT disconnect the power steering pipes or hoses from the power steering pump.

  20.  
  21. Remove the power steering pump from the front engine cover and reposition.
  22.  
  23. Disconnect the heater inlet pipe with heater hose from the lower intake manifold and reposition.
  24.  
  25. Disconnect the inlet radiator hose from the engine.
  26.  
  27. Disconnect the thermostat bypass hose from the lower intake manifold pipe.
  28.  
  29. Remove the lower intake manifold bolts.
  30.  
  31. Remove the lower intake manifold.
  32.  
  33. Loosen the valve rocker arms and remove the push rods.
  34.  
  35. Remove the lower intake manifold gaskets and seals.
  36.  
  37. Clean the lower intake manifold gasket and seal surfaces on the cylinder heads and the engine block.
  38.  
  39. Clean and inspect the lower intake manifold.
  40.  
  41. If you are replacing the lower intake manifold, perform the following steps:

    1.  
    2. Remove the ECT sensor.

      1.  
      2. Remove the thermostat.
      3.  

      To install:

      If you are replacing the lower intake manifold, perform the following steps.

      1. Install the ECT sensor.
      2.  
      3. Install the thermostat.
        NOTE
        All gasket-mating surfaces need to be free of oil, and foreign material. Use GM P/N 12346139 (Canadian P/N 10953463), or equivalent, to clean the surfaces.

      4.  
      5. Install the lower intake manifold gaskets.
      6.  
      7. Install the push rods and tighten the valve rocker arms.
      8.  
      9. With the gaskets in place apply a small drop 8-10 mm (0.31-0.39 in.) of RTV sealer GM P/N 12346286 (Canadian P/N 10953472) or equivalent to the 4 corners of the intake manifold to block joint.
      10.  
      11. Connect the 2 small drops with a bead of RTV sealer that is between 8-10 mm (0.31-0.39 in.) wide and 3.0-5.0 mm (0.12-0.20 in.) thick.
      12.  
      13. Install the lower intake manifold.
      14.  
      15. Apply sealer GM P/N 12345382, (Canadian P/N 10953489) or the equivalent to the lower intake manifold bolt threads.
        NOTE
        Maximum gasket performance is achieved when using new fasteners, which contain a thread-locking patch. If the fasteners are not replaced, a thread locking chemical must be applied to the fastener threads. Failure to replace the fasteners or apply a thread-locking chemical MAY reduce gasket sealing capability.


        NOTE
        All lower intake manifold bolts need to be cleaned, free of any foreign material, and reused only if new bolts are unavailable. Use GM P/N 12345382 (Canadian P/N 10953489) or equivalent and apply to the old intake manifold bolt threads.


        WARNING
        The manufacturer recommends the center bolts be fully torqued before the diagonal bolts to assure proper seal ability.


        NOTE
        Lower intake manifold bolts in location 6 and 7 should be torqued to specification using a crow-s foot type tool.

      16.  
      17. Install the lower intake manifold bolts.
      18.  
      19. Tighten the lower intake manifold bolts in sequence to 62 inch lbs. (7 Nm) on the first pass.
      20.  
      21. Tighten the lower intake manifold bolts (1, 2, 3, 4) in sequence to 115 inch lbs. (13 Nm) on the final pass.
      22.  
      23. Tighten the lower intake manifold bolts (5, 6, 7, 8) in sequence to 18 ft. lbs. (25 Nm) on the final pass.

        Click image to see an enlarged view

        Fig. Lower intake manifold torque sequence-3.4L engine

      24.  
      25. Connect the thermostat bypass hose to the lower intake manifold pipe.
      26.  
      27. Connect the inlet radiator hose to the engine.
      28.  
      29. Connect the heater inlet pipe to the lower intake manifold.
      30.  
      31. Install the power steering pump to the front engine cover.
      32.  
      33. Install the fuel injector rail.
      34.  
      35. Connect the fuel feed and return pipe to the fuel injector rail.
      36.  
      37. Install the fuel feed and return pipe retaining clip.
      38.  
      39. Install the fuel feed and return pipe retaining clip bolt. Tighten the fuel feed and return pipe retaining clip bolt to 71 inch lbs. (8 Nm).
        NOTE
        The fuel injector wiring harness connectors must be connected to their respective fuel injectors. Failure to connect the fuel injector connectors to their respective fuel injectors may result in excessive exhaust emissions and poor engine performance.

      40.  
      41. Install and connect the fuel injector, MAP and ECT wiring harness.
      42.  
      43. Install the wiring harness to the ECT sensor.
      44.  
      45. Install the engine right side valve rocker arm cover.
      46.  
      47. Install the engine left side valve rocker arm cover.
      48.  
      49. Install the upper intake manifold.
      50.  

      Upper Manifold

      This engine uses a 2-piece intake manifold. The upper half (often called a plenum) mounts the throttle body. The lower half of the manifold bolts to the engine and contains the fuel injectors. Please note that this engine uses a sequential multi-port fuel injection system. Injector connectors must be connected to their appropriate fuel injector assembly or engine emissions and engine performance will be seriously affected. Identify and tag for identification all wiring connectors as well as vacuum and other components as required to assure correct assembly.

      1. Before servicing the vehicle, refer to the Precautions Section.
      2.  
      3. Drain the engine coolant. Remove the coolant recovery bottle.
      4.  
      5. Relieve the fuel system pressure using the recommended procedure.
      6.  
      7. Remove or disconnect the following:

        Negative battery cable
         
        Throttle body air inlet duct
         
        Accelerator and cruise control cables and bracket from the throttle body
         
        Throttle Position (TP) sensor connector from the throttle body
         
        Idle Air Control (IAC) valve connector from the throttle body
         
        Left side spark plug wires
         
        Left side spark plug wire harness clip and harness
         
        Throttle body heater hoses
         
        Evaporative emissions (EVAP) canister purge solenoid valve vacuum hoses
         
        EVAP canister purge solenoid valve
         
        Ignition coil bracket and coils
         
        Wire harness for the Manifold Air Pressure (MAP) sensor
         
        Vacuum harness from the MAP sensor and upper intake manifold
         
        Emissions control vacuum harness
         
        Brake booster vacuum hose from the upper intake manifold
         
        Vacuum hose connection for the Heater Vent Air Conditioning (HVAC) source hose
         
        Vacuum hose connection for the fuel pressure regulator
         
        Exhaust Gas Recirculation (EGR) valve
         
        MAP sensor and bracket
         
        Alternator through-bolt bracket
         
        Upper intake manifold
         
        Upper intake manifold gasket
         
        Throttle body, if replacing the manifold

        Click image to see an enlarged view

        Fig. Removing the upper intake manifold-3.4L engine

         

      8.  

      To install:

      1. Clean all parts well. Use care in cleaning old gasket material from the machined aluminum surfaces on the plenum and manifold as sharp tools may damage sealing surfaces.
      2.  
      3. Clean the mating surfaces to the upper intake manifold and engine block. Remove any loose pieces of RTV sealer.
      4.  
      5. Install or connect the following:

        Throttle body to the upper intake manifold (if removed). Torque the bolts to 18 ft. lbs. (25 Nm).
         
        Upper intake manifold gasket
         
        Upper intake manifold
         
        MAP sensor and bracket. Torque the bolt to 44 inch lbs. (5 Nm).
         
        Upper intake manifold bolts. Torque the bolts to 18 ft. lbs. (25 Nm).
         
        EGR valve. Torque the fastener to 18 ft. lbs. (25 Nm).
         
        HVAC vacuum source hose to the upper intake manifold
         
        Fuel pressure regulator vacuum hose to the upper intake manifold
         
        Brake booster vacuum hose
         
        MAP sensor and bracket. Torque the bolt to 44 inch lbs. (5 Nm).
         
        Emissions control vacuum harness
         
        Vacuum hose for the MAP sensor and upper intake manifold
         
        Wiring harness to the MAP sensor
         
        Ignition coil bracket and coils. Torque the fasteners to 18 ft. lbs. (25 Nm).
         
        EVAP canister purge solenoid valve
         
        Vacuum hoses to the EVAP canister purge solenoid valve
         
        Throttle body heater hoses
         
        Left side spark plug wire harness clip
         
        Spark plugs wires
         
        TP sensor wire harness connector to the throttle body
         
        IAV valve wire harness connector to the throttle body
         
        Accelerator and cruise control cables and bracket to the throttle body. Torque the fasteners to 106 inch lbs. (12 Nm).
         
        Throttle body air inlet duct
         
        Negative battery cable
         

      6.  
      7. Fill the coolant system.
      8.  
      9. Fill the engine with new oil.
      10.  
      11. Turn the ignition to the ON position several times to pressurize the fuel system.
      12.  
      13. Start the engine and check for any leakage and repair if necessary.
      14.  
      15. Check and top off all fluid levels if needed.
      16.  

      3.6L Engine
      Lower Manifold
      1. Before servicing the vehicle, refer to the Precautions Section.
      2.  
      3. Turn the ignition OFF .
      4.  
      5. Remove the air inlet duct.
      6.  
      7. Relieve the fuel pressure.
      8.  
      9. Disconnect the fuel pressure and evaporative emission (EVAP) hoses from the engine.
      10.  
      11. Disconnect the barometric pressure (BARO) sensor electrical connector.
        NOTE
        Do NOT disconnect the engine control module (ECM) electrical connectors.

      12.  
      13. Remove the ECM bracket with the ECM and reposition aside.
      14.  
      15. Raise and support the vehicle.
      16.  
      17. Disconnect the intermediate steering shaft from the steering gear.
      18.  
      19. Remove and reposition the front portion of the front fender liners in order to gain access to the frame front bolts.
      20.  
      21. Lower the vehicle.
      22.  
      23. Position a floor jack at the front center section of the frame in order to support the powertrain.
      24.  
      25. Remove the frame front bolts.
      26.  
      27. Carefully lower the powertrain or raise the vehicle enough to provide access.
      28.  
      29. Disconnect the purge solenoid electrical connector.
      30.  
      31. Remove the wiring harness from the right side of the intake manifold.
      32.  
      33. Disconnect the fuel injector electrical connector.
      34.  
      35. Disconnect the intake manifold runner control solenoid electrical connector.
      36.  
      37. Remove the throttle body electrical connector.
      38.  
      39. Remove the brake booster vacuum hose from the intake manifold.
      40.  
      41. Remove the positive crankcase ventilation (PCV) hose from the intake manifold and the cylinder head.
      42.  
      43. Remove the intake manifold bolts (1-6).
      44.  
      45. Remove the intake manifold.
      46.  
      47. Disassemble the intake manifold as necessary.
      48.  
      49. Clean and inspect the intake manifold and the sealing surfaces.
      50.  

      To install

      Click image to see an enlarged view

      Fig. Lower intake manifold bolt torque sequence-3.6L engine

      1. Assemble the intake manifold as necessary.
      2.  
      3. Install the intake manifold. Tighten the bolts in the order shown to 17 ft. lbs. (23 Nm).
      4.  
      5. Install the PCV hose to the intake manifold and the cylinder head.
      6.  
      7. Install the brake booster vacuum hose to the intake manifold.
      8.  
      9. Connect the throttle body electrical connector.
      10.  
      11. Connect the intake manifold runner control solenoid electrical connector.
      12.  
      13. Connect the fuel injector electrical connector.
      14.  
      15. Install the wiring harness to the right side of the intake manifold. Tighten the bracket bolts to 89 inch lbs. (10 Nm).
      16.  
      17. Connect the purge solenoid electrical connector.
      18.  
      19. Carefully raise the powertrain or lower the vehicle in order to install the frame bolts.
      20.  
      21. Install the frame front bolts. Torque to 114 ft. lbs. (155 Nm).
      22.  
      23. Remove the floor jack.
      24.  
      25. Raise and support the vehicle.
      26.  
      27. Install the front fender liners.
      28.  
      29. Connect the intermediate steering shaft to the steering gear.
      30.  
      31. Lower the vehicle.
      32.  
      33. Install the ECM bracket with the ECM.
      34.  
      35. Connect the BARO sensor electrical connector.
      36.  
      37. Connect the fuel pressure and EVAP hoses to the engine.
      38.  
      39. Install the air inlet duct.
      40.  

      Upper Manifold
      1. Before servicing the vehicle, refer to the Precautions Section.
      2.  
      3. Turn the ignition OFF .
      4.  
      5. Remove the air inlet duct.
      6.  
      7. Relieve the fuel system pressure.
      8.  
      9. Disconnect the fuel pressure and evaporative emission (EVAP) hoses from the engine.
      10.  
      11. Disconnect the BARO sensor electrical connector.
      12.  
      13. Remove the purge line from the purge line retainer.
      14.  
      15. Remove the fuel feed hose bracket bolt and reposition the fuel feed hose.
        NOTE
        Do NOT disconnect the engine control module (ECM) electrical connectors. Do NOT remove the ECM from the ECM bracket.

      16.  
      17. Remove the ECM bracket with the ECM and reposition aside.
      18.  
      19. Raise and support the vehicle.
      20.  
      21. Disconnect the intermediate steering shaft from the steering gear.
      22.  
      23. Remove and reposition the front portion of the front fender liners in order to gain access to the frame front bolts.
      24.  
      25. Lower the vehicle.
      26.  
      27. Position a floor jack at the front center section of the frame in order to support the powertrain.
      28.  
      29. Remove the frame front bolts.
      30.  
      31. Carefully lower the powertrain or raise the vehicle enough to provide access.
      32.  
      33. Disconnect the purge solenoid electrical connector.
      34.  
      35. Remove the wiring harness from the right side of the intake manifold.
      36.  
      37. Disconnect the fuel injector electrical connector.
      38.  
      39. Remove the fuel injector electrical connector from the fuel injector electrical connector bracket.
      40.  
      41. Disconnect the intake manifold runner control solenoid electrical connector.
      42.  
      43. Disconnect the throttle body electrical connector.
      44.  
      45. Remove the brake booster vacuum hose and check valve from the intake manifold.
      46.  
      47. Remove the positive crankcase ventilation (PCV) hose from the cylinder head and the intake manifold.
      48.  
      49. Remove the intake manifold bolts (1-6).
      50.  
      51. Remove the upper intake manifold.
      52.  
      53. Remove and discard the upper intake manifold gasket.
      54.  
      55. Disassemble the intake manifold if necessary.
      56.  
      57. Clean and inspect the intake manifold and the sealing surfaces.
      58.  

      To install:

      Click image to see an enlarged view

      Fig. Upper intake manifold bolt loosening/tightening sequence-3.6L engine

      1. Assemble the intake manifold if necessary.
      2.  
      3. Install the intake manifold.
      4.  
      5. Install the intake manifold bolts (1-6). Tighten the bolts in the order shown to 17 ft. lbs. (23 Nm).
      6.  
      7. Install the PCV hose to the intake manifold and the cylinder head.
      8.  
      9. Install the brake booster vacuum hose and check valve to the brake booster.
      10.  
      11. Install the throttle body electrical connector.
      12.  
      13. Connect the intake manifold runner control solenoid electrical connector.
      14.  
      15. Install the fuel injector electrical connector to the fuel injector electrical connector bracket.
      16.  
      17. Install the fuel injector bracket.
      18.  
      19. Connect the fuel injector electrical connector.
      20.  
      21. Install the wiring harness and bracket to the right side of the intake manifold. Tighten the bracket bolts to 89 inch lbs. (10 Nm).
      22.  
      23. Connect the purge solenoid electrical connector.
      24.  
      25. Carefully raise the powertrain or lower the vehicle in order to install the frame bolts.
      26.  
      27. Install the frame front bolts. Torque to 114 ft. lbs. (155 Nm).
      28.  
      29. Remove the floor jack.
      30.  
      31. Raise and support the vehicle.
      32.  
      33. Install the front fender liners.
      34.  
      35. Connect the intermediate steering shaft to the steering gear.
      36.  
      37. Lower the vehicle.
      38.  
      39. Install the ECM bracket with the ECM.
      40.  
      41. Install the fuel feed hose bracket and the bracket bolt. Tighten the bracket bolt to 89 inch lbs. (10 Nm).
      42.  
      43. Connect the BARO sensor electrical connector.
      44.  
      45. Install the purge line to the purge line retainer.
      46.  
      47. Connect the fuel pressure and EVAP hoses to the engine.
      48.  
      49. Install the air inlet duct.
      50.  

       
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