Envoy, Rainer, Trailblazer 2006-2007

Intake Manifold

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Removal & Installation



4.2L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Drain the engine cooling system.
  8.  
  9. Remove or disconnect the following:

    Throttle body
     
    Powertrain Control Module (PCM)
     
    All electrical harnesses from the engine harness bracket
     
    Front differential vent hose from the bracket clip
     
    Engine harness bracket bolt and bracket
     
    Manifold Absolute Pressure (MAP) sensor connector
     
    Crankcase ventilation hose
     
    Brake hose from the booster
     
    Alternator
     
    Intake manifold bolts and manifold.
     
    Manifold gasket
     

  10.  

To install:

  1. Clean the gasket mounting surfaces. Be sure to inspect the manifold for warpage and/or cracks. If necessary, replace it.
  2.  
  3. Properly position a new intake manifold gasket.
  4.  
  5. Install or connect the following:

    Intake manifold and bolts. Torque the bolts to 16 ft. lbs. (22 Nm).
     
    Alternator
     
    Brake hose to the booster
     
    Crankcase ventilation hose, lubricating the inner diameter first with 12345884, or equivalent lubricant
     
    MAP sensor electrical connector
     
    Engine harness bracket. Tighten the retaining bolt to 37 ft. lbs. (50 Nm).
     
    Front differential vent hose to the engine harness bracket clip
     
    All harnesses to their original locations onto the engine harness bracket
     
    PCM
     
    Throttle body
     
    Negative battery cable
     

  6.  
  7. Refill the engine cooling system.
  8.  

5.3L Engine

NOTE
The intake manifold, throttle body, fuel rail and injectors can be removed as an assembly. If you are not servicing these components individually, remove the intake manifold as a complete assembly.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Drain the engine cooling system.
  8.  
  9. Remove or disconnect the following:

    Air cleaner outlet duct
     
    A/C compressor pressure switch electrical connector
     
    Harness clip from the cylinder head and fuel rail
     
    Mass Airflow/Intake Air Temperature sensor connector
     

  10.  
  11. Disconnect the electrical connectors from the following:
    1. Main coil
    2.  
    3. Electronic Throttle Control (ETC)
    4.  
    5. Fuel injectors. Matchmark the connectors, pull the Connector Position Assurance (CPA) retainer up 1 click. Push the tab on the connector in, then detach the injector connector.

      Alternator connector
       
      Evaporative emission (EVAP) purge solenoid electrical connector
       
      Knock Sensor (KS) electrical connector
       
      Main coil
       
      Fuel injector electrical connector
       
      Electrical harness clips from the fuel rail
       
      KS harness electrical connector from the intake manifold
       
      Positive Crankcase Ventilation (PCV) valve hose and valve
       
      Heater water shutoff valve actuator inlet hose from the intake manifold
       
      EVAP purge solenoid vent tube
       
      Vacuum brake booster hose from the rear of the intake manifold
       
      Upper engine wire harness retainer nut. Position the wire harness aside.
       
      Intake manifold bolts
       
      Intake manifold and gaskets. Discard the gaskets.
       

    6.  

  12.  

To install:

  1. Clean the gasket mounting surfaces. Be sure to inspect the manifold for warpage and/or cracks. If necessary, replace it.
  2.  
  3. Properly position a new intake manifold gasket.

    Click image to see an enlarged view

    Fig. Make sure to use NEW intake manifold gaskets (1)-5.3L engine



    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold-5.3L engine

  4.  
  5. Apply a 0.20 in. (5mm) band of a suitable threadlocking material to the intake manifold bolt threads.
  6.  
  7. Install or connect the following:

    Intake manifold and bolts. Torque the bolts, in sequence to 44 inch lbs. (5 Nm), then to 89 inch lbs. (10 Nm).

    Click image to see an enlarged view

    Fig. Intake manifold bolt tightening sequence-5.3L engine

     
    Route the electrical harness into position over the engine.
     
    Engine harness bracket nut and tighten to 89 inch lbs. (10 Nm)
     
    Vacuum brake booster hose to the rear of the intake manifold
     
    EVAP purge solenoid valve
     
    Heater water shutoff valve actuator inlet hose to the intake manifold
     
    PCV valve and hose
     
    EVAP purge solenoid, KS, MAP sensor, main coil & fuel injector electrical connectors
     
    Harness clips to the fuel rail
     
    Alternator electrical connector
     
    Main coil, ETC, fuel injector electrical connectors
     
    Electrical harness clips to the fuel rail
     
    A/C compressor pressure switch electrical connector
     
    Harness clip to the cylinder head
     
    Mass Airflow/Intake Air Temperature sensor connector
     
    Air cleaner outlet duct
     
    Fuel fill cap
     
    Negative battery cable
     

  8.  
  9. Refill the engine cooling system.
  10.  

6.0L Engine

NOTE
The intake manifold, throttle body, fuel rail and injectors can be removed as an assembly. If you are not servicing these components individually, remove the intake manifold as a complete assembly.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Drain the engine cooling system.
  8.  
  9. Remove or disconnect the following:

    A/C compressor pressure switch electrical connector
     
    Mass Airflow/Intake Air Temperature sensor connector
     
    Electronic Throttle Control (ETC)
     

  10.  
  11. Remove the right side connector position assurance (CPA) retainer from the engine wiring harness main ignition coil electrical connector.
  12.  
  13. Disconnect the right side engine wiring harness electrical connector from the main ignition coil electrical connector.
  14.  
  15. Disconnect the right side engine wiring harness electrical connectors from the fuel injectors.
  16.  
  17. Perform the following steps (for the left and right sides) in order to disconnect the fuel injector electrical connectors.
    1. Mark the connectors to their corresponding injectors to ensure correct reassembly.

      Click image to see an enlarged view

      Fig. Pull the CPA retainer (2) on the connector up one click, then push the tab (1) on the connector in to disconnect the fuel injector electrical connector-6.0L engine

    2.  
    3. Pull the connector position assurance (CPA) retainer (2) on the connector up one click.
    4.  
    5. Push the tab (1) on the connector in.
    6.  
    7. Disconnect the fuel injector electrical connector.
    8.  
    9. Repeat the steps for each injector electrical connector.
    10.  

  18.  
  19. Remove the left side CPA retainer from the engine wiring harness main ignition coil electrical connector.
  20.  
  21. Disconnect the left side engine wiring harness electrical connector from the main ignition coil electrical connector.
  22.  
  23. Disconnect the left side engine wiring harness electrical connectors from the fuel injectors.
  24.  
  25. Disconnect the engine wiring harness electrical connector from the alternator.
  26.  
  27. Disconnect the engine wiring harness electrical connector from the manifold absolute pressure (MAP) sensor.
  28.  
  29. Disconnect the engine wiring harness electrical connector from the evaporative emission (EVAP) canister purge solenoid valve.
  30.  
  31. Disconnect the positive crankcase ventilation (PCV) hose.

    Click image to see an enlarged view

    Fig. Disconnect the EVAP purge solenoid vent tubes (1 and 2)-6.0L engine

  32.  
  33. Disconnect the EVAP purge solenoid vent tubes (1, 2).
  34.  
  35. Disconnect the fuel feed pipe from the fuel rail.
  36.  
  37. Reposition the vacuum brake booster hose clamp at the brake booster and disconnect the vacuum brake booster hose from the brake booster.
  38.  
  39. Remove the engine wire harness retainer nut and reposition the upper engine wire harness aside.
  40.  
  41. Remove the drive belt.
  42.  
  43. Remove the right alternator bolt, then loosen the left alternator bolt and reposition the alternator to the left.
  44.  
  45. Remove the intake manifold bolts.
  46.  
  47. Remove the intake manifold and gaskets. Discard the gaskets.
  48.  

To install:

  1. Clean the gasket mounting surfaces. Be sure to inspect the manifold for warpage and/or cracks. If necessary, replace it.
  2.  
  3. Install NEW intake manifold gaskets to the intake manifold.
  4.  
  5. Install the intake manifold.
  6.  
  7. Apply a 0.2 inch (5mm) bead threadlock to the threads of the intake manifold bolts.

    Click image to see an enlarged view

    Fig. Intake manifold bolt tightening sequence-6.0L engine

  8.  
  9. Install the intake manifold bolts. Torque the bolts, in sequence to 44 inch lbs. (5 Nm), then to 89 inch lbs. (10 Nm).
  10.  
  11. Position the alternator and install the right alternator bolt and tighten the left alternator bolt to 37 ft. lbs. (50 Nm).
  12.  
  13. Install the drive belt.
  14.  
  15. Route the electrical harness into position over the engine. Install the engine harness bracket nut and tighten to 89 inch lbs. (10 Nm).
  16.  
  17. Connect the vacuum brake booster hose to the brake booster and position the vacuum brake booster hose clamp at the brake booster.
  18.  
  19. Connect the fuel feed pipe to the fuel rail.
  20.  
  21. Install the EVAP purge solenoid vent tubes (1, 2).
  22.  
  23. Install the PCV hose.
  24.  
  25. Connect the engine wiring harness electrical connector to the MAP sensor.
  26.  
  27. Connect the engine wiring harness electrical connector to the EVAP canister purge solenoid valve.
  28.  
  29. Connect the engine wiring harness electrical connector to the alternator.
  30.  
  31. Connect the left side engine wiring harness electrical connector to the main ignition coil electrical connector.
  32.  
  33. Install the left side CPA retainer to the engine wiring harness main ignition coil electrical connector.
  34.  
  35. Connect the left side engine wiring harness electrical connectors to the fuel injectors.
  36.  
  37. Perform the following steps (for the left and right sides) in order to connect the fuel injector electrical connectors:
    1. Install the connectors to their corresponding injectors to ensure correct reassembly.
    2.  
    3. Connect the fuel injector electrical connector.
    4.  
    5. Push the CPA retainer (2) on the connector in one click.
    6.  
    7. Repeat the steps for each injector electrical connector.
    8.  

  38.  
  39. Connect the engine wiring harness electrical connector to the ETC.
  40.  
  41. Connect the right side engine wiring harness electrical connector to the main ignition coil electrical connector.
  42.  
  43. Install the right side CPA retainer to the engine wiring harness main ignition coil electrical connector.
  44.  
  45. Connect the right side engine wiring harness electrical connectors to the fuel injectors.
  46.  
  47. Connect the engine harness wiring harness electrical connector to the MAF/IAT sensor.
  48.  
  49. Connect the engine wiring harness electrical connector to the A/C compressor pressure switch.
  50.  
  51. Install the fuel fill cap.
  52.  
  53. Connect the negative battery cable.
  54.  
  55. Use the following procedure in order to inspect for leaks:
    1. Turn the ignition ON, with the engine OFF, for 2 seconds.
    2.  
    3. Turn the ignition OFF for 10 seconds.
    4.  
    5. Turn the ignition ON, with the engine OFF.
    6.  
    7. Inspect for fuel leaks.
    8.  

  56.  

 
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