Camaro, Firebird, 1999 - 2002

Intake Manifold

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Removal & Installation



3.8L Engines
Lower Manifold
  1. Before servicing the vehicle, refer to the Precautions Section.
    NOTE
    There are 2 bolts that are hidden under the upper manifold. They are located in the front and left rear corners of the lower manifold. It is necessary to remove the upper manifold to service the lower manifold.

  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Upper intake manifold
     
    Engine Coolant Temperature (ECT) sensor
     
    Lower intake manifold

    Click image to see an enlarged view

    Fig. Lower intake manifold torque sequence-3.8L engine

     

  4.  

To install:

  1. Install or connect the following:

    New gaskets and seals
     
    Lower manifold. Torque the manifold bolts in sequence to 11 ft. lbs. (15 Nm).
     
    ECT sensor
     
    Upper intake manifold
     
    Negative battery cable
     

  2.  

Upper Manifold
  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:

    Negative battery cable
     
    Intake Air Temperature (IAT) sensor electrical connector
     
    Drive belt tensioner
     
    Fuel pressure regulator vacuum and Evaporative Emission (EVAP) 1canister purge harness from the manifold vacuum source, purge solenoid valve and the fuel pressure regulator valve
     
    Manifold vacuum source electrical connector
     
    Manifold vacuum source screws
     
    Manifold vacuum source from the upper intake manifold
     
    Canister purge solenoid valve electrical connector and hose
     
    Evaporative emissions canister purge solenoid valve
     
    Idle Air Control (IAC) valve
     
    Fuel lines from the fuel rail
     
    EVAP pipe at the engine
     
    Accelerator control cable bracket and control cables from the throttle body
     
    Ignition control module and coil pack assembly
     
    Brake booster hose from the upper manifold
     
    Alternator brace
     
    Throttle Position Sensor (TPS) electrical connector
     
    Mass Air Flow (MAF) sensor electrical connector
     
    Wiring harness from the fuel rail clips
     
    Thermostat housing
     
    Electrical connectors from the fuel injectors
     
    Fuel rail
     
    Upper intake manifold
     

  8.  

To install:

Click image to see an enlarged view

Fig. Upper intake manifold torque sequence-1999 3.8L engine



Click image to see an enlarged view

Fig. Upper intake manifold torque sequence-2000-02 3.8L engine

  1. Install the 1999 models upper intake manifold using a new gasket. Torque the bolts as follows:
    1. Bolts 1-10, in sequence: 11 ft. lbs. (15 Nm).
    2.  
    3. Coolant outlet bolts: 20 ft. lbs. (27 Nm).
    4.  
    5. Side bolts: 22 ft. lbs. (30 Nm).
    6.  

  2.  
  3. Install the 2000-02 models upper intake manifold using a new gasket. Torque the bolts as follows:
    1. Tighten the upper intake manifold bolts in sequence: 11 ft. lbs. (15 Nm).
    2.  
    3. Tighten the nine upper intake manifold bolts to 89 inch lbs. (10 Nm).
    4.  
    5. Tighten the two upper intake manifold bolts to 22 ft. lbs. (30 N).
    6.  

  4.  
  5. Install the fuel rail as follows:
    1. Install new fuel injector O-rings lubricated with engine oil.
    2.  
    3. Install the fuel injectors into the manifold bores.
    4.  
    5. Insert the fuel rail until the injectors are properly seated.
    6.  
    7. Torque the nuts to 75 inch lbs. (8.5 Nm).
    8.  

  6.  
  7. Install or connect the following:

    Fuel injector electrical connectors
     
    Thermostat and thermostat housing. Torque the housing bolts to 20 ft. lbs. (27 Nm).
     
    Throttle body and tighten the retainers to 89 inch lbs. (10 Nm)
     
    Wiring harness to the fuel rail clips
     
    Electrical connectors to the IAC, TPS, MAF and IAT sensors
     
    Alternator brace
     
    Brake booster hose
     
    Ignition control module and coil pack assembly
     
    Accelerator cable bracket and cruise control cables to the throttle body. Torque the bracket bolts to 12 ft. lbs. (16 Nm).
     
    Accelerator and cruise control cables
     
    Fuel lines to the fuel rail
     
    IAC valve
     
    Fuel pressure regulator
     
    Canister purge harness
     
    Evaporative emissions canister purge solenoid valve
     
    MAP sensor and vacuum source
     
    Drive belt tensioner. Torque the bolts to 37 ft. lbs. (50 Nm).
     
    Air intake duct
     
    IAT sensor connector
     
    Drive belt
     
    Negative battery cable
     

  8.  
  9. Refill the coolant system.
  10.  
  11. Start the engine and check for leaks.
  12.  

5.7L Engines
1999 Models
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the coolant system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Transmission fluid level indicator tube bolt
     
    Fuel lines from the fuel rail
     
    Vapor line from the fuel vapor purge valve
     
    Intake Air Temperature (IAT) sensor electrical connector
     
    Mass Airflow (MAF) sensor electrical connection
     
    Air inlet duct
     
    Idle Air Control (IAC) valve and Throttle Position Sensor (TPS) electrical connections from the throttle body
     
    Drive belt
     
    Exhaust Gas Recirculation (EGR) solenoid electrical connector
     
    EGR valve pipe
     
    Cruise control and throttle cables from the throttle body
     
    Cruise control servo bracket
     
    Fuel injector electrical connectors
     
    Fuel rail
     
    Manifold Absolute Pressure (MAP) sensor electrical connector
     
    Vacuum hose from the vacuum port on the MAP sensor housing
     
    Knock sensor harness electrical connector
     
    Remaining electrical connections from the intake manifold
     
    Fresh air tube from the throttle body and rocker cover
     
    Vapor vent tube from the throttle body
     
    Throttle body heater outlet hose from the throttle body
     
    Evaporative emission (EVAP) canister purge tube
     
    Canister purge valve and bracket from the intake manifold
     
    Intake manifold bolts and the manifold

    Click image to see an enlarged view

    Fig. Intake manifold torque sequence-5.7L (VIN G) engine

     

  8.  

To install:

  1. Install the intake manifold with new gaskets.
  2.  
  3. Torque the bolts in sequence as follows:
    1. First pass in sequence: 44 inch lbs. (5 Nm)
    2.  
    3. Final pass in sequence to 89 inch lbs. (10 Nm).
    4.  

  4.  
  5. Install or connect the following:

    Canister purge valve and bracket to the intake manifold
     
    EVAP canister purge tube
     
    Throttle body heater outlet hose to the throttle body
     
    Vapor vent tube to the throttle body
     
    Fresh air tube to the throttle body and rocker cover
     
    PCV valve pipe from the rocker cover
     
    PCV pipe strap nut
     
    Knock sensor harness electrical connector
     
    MAP sensor electrical connector
     
    Vacuum hose to the vacuum port on the MAP sensor housing
     
    Fuel rail
     
    Fuel injector electrical connectors
     
    All remaining electrical connections
     
    Cruise control servo bracket
     
    Cruise control and throttle cables to the throttle body
     

  6.  
  7. Apply a light coating of clean engine oil to a NEW O-ring seal and install the seal onto the EGR valve pipe.

    EGR valve pipe into the intake manifold. Finger start the EGR valve pipe to the intake manifold bolt and the EGR valve pipe to the cylinder head bolts.
     

  8.  
  9. Finger start a NEW EGR valve pipe exhaust manifold gasket and bolts and tighten as follows:
    1. Tighten the EGR valve pipe to the exhaust manifold bolts to 22 ft. lbs. (30 Nm).
    2.  
    3. Tighten the EGR valve pipe-to-cylinder head bolts to 37 ft. lbs. (50 Nm).
    4.  
    5. Tighten the EGR valve pipe-to-intake manifold bolt to 89 inch lbs. (10 Nm).

      EGR solenoid electrical connector
       
      Drive belt
       
      IAC valve and TPS electrical connections to the throttle body
       
      Air inlet duct
       
      IAT and MAF sensor electrical connector
       
      Fuel lines to the fuel rail
       
      Vapor line to the fuel vapor purge valve
       
      Transmission fluid level indicator tube bolt
       
      Negative battery cable
       

    6.  

  10.  

2000-01 Models
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the coolant system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Transmission fluid level indicator tube bolt
     
    Fuel lines from the fuel rail
     
    Vapor line from the fuel vapor purge valve
     
    Intake Air Temperature (IAT) sensor electrical connector
     
    Air inlet duct
     
    Idle Air Control (IAC) valve and Throttle Position Sensor (TPS) electrical connections from the throttle body
     
    Drive belt
     
    Exhaust Gas Recirculation (EGR) solenoid electrical connector
     
    EGR valve pipe
     
    O-ring seal from the EGR valve pipe. Discard the exhaust manifold gasket and O-ring seal.
     
    Cruise control and throttle cables from the throttle body
     
    Cruise control servo bracket
     
    Fuel injector electrical connectors
     
    Secondary Air Injection (AIR) solenoid electrical connector
     
    Fuel rail
     
    Fresh air tube from the throttle body and rocker cover
     
    Vapor vent tube from the throttle body
     
    Throttle body heater outlet hose from the throttle body
     
    Evaporative emission (EVAP) canister purge tube
     
    Canister purge valve and bracket from the intake manifold
     
    Knock sensor harness electrical connector
     
    Manifold Absolute Pressure (MAP) sensor electrical connector
     
    Vacuum hose from the vacuum port on the MAP sensor housing
     
    Remaining electrical connections from the intake manifold
     
    Intake manifold bolts and the manifold
     

  8.  

To install:

  1. Install the intake manifold with new gaskets.
  2.  
  3. Torque the bolts in sequence as follows:
    1. First pass in sequence: 44 inch lbs. (5 Nm)
    2.  
    3. Final pass in sequence to 89 inch lbs. (10 Nm).
    4.  

  4.  
  5. Install or connect the following:

    MAP sensor electrical connector
     
    Vacuum hose from the vacuum port on the MAP sensor housing
     
    Knock sensor harness electrical connector
     
    Canister purge valve and bracket to the intake manifold
     
    EVAP canister purge tube
     
    Throttle body heater outlet hose to the throttle body
     
    Vapor vent tube to the throttle body
     
    Fresh air tube to the throttle body and rocker cover
     
    Fuel rail
     
    AIR solenoid electrical connector
     
    Fuel injector electrical connectors
     
    All remaining electrical connections
     
    Cruise control servo bracket
     
    Cruise control and throttle cables to the throttle body
     

  6.  
  7. Apply a light coating of clean engine oil to a NEW O-ring seal and install the seal onto the EGR valve pipe.

    EGR valve pipe into the intake manifold. Finger start the EGR valve pipe to the intake manifold bolt and the EGR valve pipe to the cylinder head bolts.
     

  8.  
  9. Finger start a NEW EGR valve pipe exhaust manifold gasket and bolts and tighten as follows:
    1. Tighten the EGR valve pipe-to-intake manifold bolt to 89 inch lbs. (10 Nm).
    2.  
    3. Tighten the EGR valve pipe-to-cylinder head bolts to 37 ft. lbs. (50 Nm).
    4.  
    5. Tighten the EGR valve pipe to the exhaust manifold bolts to 22 ft. lbs. (30 Nm).

      EGR solenoid electrical connector
       
      Drive belt
       
      IAC valve and TPS electrical connections to the throttle body
       
      Air inlet duct
       
      IAT and MAF sensor electrical connector
       
      Fuel lines to the fuel rail
       
      Vapor line to the fuel vapor purge valve
       
      Transmission fluid level indicator tube bolt
       

    6.  

  10.  
  11. Refill the cooling system.

    Negative battery cable
     

  12.  

2002 Models
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the coolant system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Throttle body
     
    Fuel rail
     
    Transmission fluid level indicator tube bolt
     
    Accelerator control cable bracket nut
     
    Accelerator control cable and cruise control servo bracket
     
    Positive Crankcase Ventilation (PCV) tube from the right rocker arm cover and throttle body
     
    PCV valve pipe from the left rocker arm cover
     
    PCV valve pipe strap nut
     
    PCV valve pipe from the right rocker arm cover and intake manifold
     
    Vapor line from the Evaporative Emission (EVAP) canister purge solenoid valve
     
    EVAP canister purge solenoid valve connection
     
    EVAP canister purge tube from the intake manifold and EVAP canister purge solenoid valve
     
    EVAP canister purge solenoid valve (with bracket) from the intake manifold
     
    Knock Sensor (KS) harness connector
     
    KS wire harness connector from the fuel rail stop bracket
     
    Secondary Air Injection (AIR) vacuum control solenoid valve connection
     
    AIR shut off valve vacuum harness from the shut off valve and vacuum tee
     
    AIR vacuum control solenoid valve (with bracket) from the intake manifold
     
    Power brake booster vacuum hose from the vacuum port
     
    Manifold Absolute Pressure (MAP) sensor connector
     
    Vacuum hose from the tee on the rear vacuum port
     
    MAP sensor from the rear of the intake manifold
     
    Intake manifold bolts and fuel rail stop bracket
     
    Intake manifold
     
    Intake manifold-to-cylinder head gaskets and discard
     

  8.  

To install:



New intake manifold-to-cylinder head gaskets
 
Intake manifold
 

  1. Apply threadlock GM U.S. P/N 12345382 to the threads of the intake manifold bolts.
    CAUTION
    The fuel rail stop bracket must be installed onto the engine assembly. The stop bracket serves as a protective shield for the fuel rail in the event of a vehicle frontal crash. If the fuel rail stop bracket is not installed and the vehicle is involved in a frontal crash, fuel could be sprayed possibly causing a fire and personal injury from burns.

  2.  
  3. Install or connect the following:

    Fuel rail stop bracket
     
    Intake manifold bolts and tighten in a first pass in sequence to 44 inch lbs. (5 Nm) and a final pass in sequence to 89 inch lbs. (10 Nm)
     
    MAP sensor
     
    All vacuum hoses
     
    AIR vacuum control solenoid valve (with bracket) to the intake manifold
     
    AIR shut off valve vacuum harness to the AIR shut off valve and vacuum tee
     
    AIR vacuum control solenoid valve connection
     
    KS sensor wire harness connector to the fuel rail stop bracket
     
    KS sensor harness connection
     
    EVAP canister purge solenoid valve (with bracket) to the intake manifold
     
    Vapor line to the EVAP canister purge solenoid valve
     
    EVAP canister purge tube to the intake manifold and EVAP canister purge solenoid valve
     
    EVAP canister purge solenoid valve connection
     
    Vapor line to the EVAP canister purge solenoid valve
     
    PCV valve pipe to the right rocker arm cover and intake manifold
     
    PCV valve pipe strap nut
     
    PCV valve pipe to the left rocker arm cover and throttle body
     
    PCV tube to the right rocker arm cover
     
    Accelerator control cable and cruise control servo bracket
     
    Accelerator control cable bracket nut
     
    Transmission fluid level indicator tube bolt
     
    Fuel rail
     
    Throttle body
     
    Negative battery cable
     

  4.  

 
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