GrandPrix, Impala 2006-2008, Monte Carlo 2006-2007

Intake Manifold

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Removal & Installation



3.4L Engine
  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.



    Intake Air Temperature (IAT) sensor electrical connector
     
    Throttle body air inlet duct
     
    Throttle and cruise control cables with bracket
     
    Throttle Position Sensor (TPS) electrical connector
     
    Idle Air Control (IAC) valve electrical connector
     
    Camshaft Position (CMP) sensor wiring harness from the intake
     
    Spark plug wires from the intake
     
    Thermostat bypass hoses from the throttle body
     
    Ignition coil bracket with the coils, the purge solenoid and the vacuum canister solenoid
     
    Vacuum lines from the upper intake manifold
     
    Manifold Absolute Pressure (MAP) sensor
     
    Alternator brace
     
    Exhaust Gas Recirculation (EGR) valve
     
    Upper intake manifold
     
    Both rocker arm covers
     
    Engine Coolant Temperature (ECT) sensor electrical connector
     
    Fuel injector and MAP wiring harness
     
    Fuel injector electrical connectors
     
    Fuel lines from the fuel rail and fuel line bracket
     
    Fuel rail with the injectors
     
    Power steering pump and move it aside without disconnecting the lines
     
    Coolant inlet pipe from the coolant outlet housing
     
    Coolant bypass hose
     
    Upper radiator hose at thermostat housing
     
    Lower intake manifold bolts
     



    Rocker arm bolts, rocker arms and pushrods
     
    Intake manifold
     

  8.  

To install:

Click image to see an enlarged view

Fig. Lower intake manifold torque sequence-3.4L engines

  1. Place a 8-12mm 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, tighten the vertical bolts before the diagonal bolts.



    Intake manifold gasket
     
    Pushrods and rocker arms
     
    Rocker arm bolts and torque the bolts to 89 inch lbs. (10 Nm) plus an additional 30 degree turn
     



    Lower intake manifold and torque the bolts to 115 inch lbs. (13 Nm) and if equipped, tighten the vertical and diagonal lower intake manifold bolts to 62 inch lbs. (7 Nm)
     
    Both rocker arm covers and torque the bolts to 89 inch lbs. (10 Nm)
     
    Thermostat bypass hose
     
    Upper radiator hose
     
    Heater inlet pipe and heater hose to the lower intake
     
    Power steering pump and torque the bolts to 25 ft. lbs. (34 Nm)
     
    Fuel fail with the injectors
     
    Fuel feed and return lines
     
    Fuel injector electrical connectors
     
    ECT sensor electrical connector
     
    Upper intake manifold using a new gasket and torque the bolts to 18 ft. lbs. (25 Nm)
     
    EGR valve
     
    Alternator brace
     
    Vacuum lines
     
    MAP sensor
     
    Ignition coil bracket with the coils, the purge solenoid and the vacuum canister solenoid
     
    Thermostat bypass pipe coolant hoses to the throttle body
     
    CMP sensor wiring harness to the intake
     
    Spark plug wires
     
    TPS electrical connector
     
    IAC valve electrical connector
     
    Throttle and cruise control cables with the bracket and torque the bolts to 115 inch lbs. (13 Nm) and the nuts to 89 inch lbs. (10 Nm)
     
    Throttle body air inlet duct
     
    IAT sensor electrical connector
     
    Negative battery cable
     

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

  6.  
  7. Start the vehicle and check for leaks, repair if necessary.
  8.  

3.5L & 3.9L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Partially drain the engine coolant.
  4.  
  5. Remove or disconnect the following:
    NOTE
    Disengage the snap-lock retainers by pushing toward the camshaft covers and lifting.


    NOTE
    The manifold-to-cylinder head seals are reusable unless cut or damaged.



    Negative battery cable
     
    Throttle body air inlet duct
     
    Fuel injector sight shield
     
    Throttle and cruise control cables from the throttle body with the bracket
     
    Coolant hoses from the throttle body
     
    Fuel lines from the fuel supply rail
     
    Fuel vapor line from the Evaporative Emission (EVAP) canister purge solenoid
     
    Brake booster vacuum hose
     
    Air conditioning vacuum hose from the engine
     
    Surge tank inlet pipe retainer from the fuel supply rail
     
    Fuel injector electrical connectors
     
    Throttle Position Sensor (TPS) electrical connectors
     
    Idle Air Control (IAC) valve electrical connector
     
    EVAP canister purge solenoid connector
     
    Manifold Absolute Pressure (MAP) sensor connector
     
    Wiring harness channels from the camshaft covers
     
    Vacuum tube from the fuel pressure regulator
     
    Positive Crankcase Ventilation (PCV) valve and both feed tubes
     
    Exhaust Gas Recirculation (EGR) valve outlet pipe
     
    Fuel supply rail with injectors
     



    Throttle body coolant hose
     
    Intake manifold
     



    Click image to see an enlarged view

    Fig. Intake manifold assembly-3.5L engine

  6.  

To install:

  1. Install or connect the following:

    New intake manifold-to-cylinder head seals
     
    Intake manifold and torque the bolts, in a circular pattern, starting from the center to 62 inch lbs. (7 Nm)
     
    Throttle body heater hose
     
    New O-rings on the fuel injectors
     
    Fuel supply rail with injectors
     
    EGR pipe and torque the intake manifold bolt to 89 inch lbs. (10 Nm) and the coolant crossover bolt to 18 ft. lbs. (24 Nm)
     
    PCV valve and related tubing
     
    Brake booster vacuum hose
     
    Fuel pressure regulator vacuum hose
     
    Air conditioning vacuum hose
     
    Engine wiring harness with channel to the camshaft covers and torque the bolts to 89 inch lbs. (10 Nm)
     
    Surge tank pipe retainer to the fuel supply rail
     
    TPS electrical connector
     
    IAC electrical connector
     
    EVAP solenoid electrical connector
     
    MAP sensor electrical connector
     
    Fuel injector electrical connectors
     
    Coolant hoses to the throttle body
     
    Throttle and cruise control cables to the throttle body
     
    Fuel lines to the fuel supply rail
     
    Fuel vapor line to the purge solenoid
     
    Fuel injector sight shield
     
    Throttle body air inlet duct
     
    Negative battery cable
     

  2.  
  3. Refill the cooling system.
  4.  
  5. Start the engine and check for leaks, repair if necessary.
  6.  

3.8L Engine
With Supercharger
  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
     
    Exhaust Gas Recirculation (EGR) valve heat shield
     
    Supercharger drive belt
     
    Right side spark plug wires
     
    Alternator rear brace
     
    Fuel injector electrical connectors
     
    Manifold Absolute Pressure (MAP) sensor and bracket
     
    Fuel feed and return lines
     
    Fuel rail with the injectors
     
    Boost control solenoid
     
    Cruise control and throttle cables
     
    Air inlet duct
     
    Supercharger
     
    Upper radiator hose
     
    Thermostat housing
     
    EGR tube
     
    Temperature sensor electrical connector
     
    Intake manifold
     

  8.  

To install:

  1. Install or connect the following:

    Intake manifold with new gaskets and torque the bolts to 11 ft. lbs. (15 Nm)
     
    Temperature sensor electrical connector
     
    EGR tube
     
    Thermostat housing with a new gasket and torque the bolts to 20 ft. lbs. (27 Nm)
     
    Upper radiator hose
     
    Supercharger with new gaskets and torque the bolts to 17 ft. lbs. (23 Nm)
     
    Air inlet duct
     
    Cruise control and throttle cables
     
    Boost control solenoid and torque the bolts to 72 inch lbs. (8 Nm)
     
    Fuel rail and torque the hold down bolts to 7 ft. lbs. (10 Nm)
     
    Fuel feed and return lines
     
    MAP sensor and bracket
     
    Fuel injector electrical connectors
     
    Alternator rear brace and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Spark plug wires
     
    Supercharger drive belt
     
    EGR valve heat shield
     
    Fuel injector sight shield
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

Without Supercharger

NOTE
There are 2 bolts hidden beneath the upper intake manifold. These bolts are located in the right front and left rear corners of the lower intake manifold. It is necessary to remove the upper intake manifold to service the lower intake 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
     
    Fuel injector sight shield and air inlet duct
     
    Spark plug wires from the right side of the engine
     
    Evaporative emissions (EVAP) canister purge solenoid electrical connector
     
    Fuel feed and return lines
     
    Vacuum lines from the throttle body
     
    Accessory drive belt
     
    Alternator and bracket
     
    Fuel injector electrical connectors
     
    Fuel pressure regulator vacuum line
     
    Fuel rail hold down bolts
     
    Fuel rail with injectors
     
    Brake booster hose from the manifold
     
    Exhaust Gas Recirculation (EGR) valve heat shield
     
    Throttle cables from the throttle body lever
     
    Throttle body support bracket
     
    Manifold Absolute Pressure (MAP) sensor electrical connector
     
    Upper intake plenum
     
    Drive belt tensioner
     
    EGR valve outlet pipe
     
    Upper radiator hose
     
    Engine Coolant Temperature (ECT) sensor electrical connector
     
    Evaporative emissions canister purge solenoid valve
     
    Alternator brace
     
    Lower intake manifold
     

  8.  

To install:

Click image to see an enlarged view

Fig. Always tighten the lower intake manifold bolts in sequence-3.8L (VIN 1 and K) engines



Click image to see an enlarged view

Fig. Upper intake manifold bolt tightening sequence-3.8L (VIN 1 and K) engines

  1. Install or connect the following:

    New intake manifold gaskets
     
    Intake manifold and torque the bolts, in sequence, to 11 ft. lbs. (15 Nm)
     
    Evaporative emissions canister purge solenoid valve
     
    Alternator brace
     
    ECT sensor electrical connector
     
    Upper radiator hose
     
    EGR valve outlet pipe
     
    Drive belt tensioner and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Intake plenum using a new gasket and torque the bolts, in sequence, to 89 inch lbs. (10 Nm)
     
    MAP sensor electrical connector
     
    Throttle body support bracket
     
    Throttle cables to the throttle body lever
     
    EGR heat shield
     
    Brake booster vacuum hose
     
    Fuel rail assembly and torque the bolts to 84 inch lbs. (10 Nm)
     
    Fuel pressure regulator vacuum line
     
    Fuel injector electrical connectors
     
    Alternator bracket and torque the nut and bolt to 37 ft. lbs. (50 Nm)
     
    Alternator and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Accessory drive belt
     
    Vacuum lines to the throttle body
     
    Fuel feed and return lines
     
    EVAP canister purge solenoid electrical connector
     
    Spark plug wires to the rear bank spark plugs
     
    Air inlet duct
     
    Fuel injector sight shield
     
    Negative battery cable
     

  2.  
  3. Pressurize the fuel system.
  4.  
  5. Refill and bleed the cooling system.
  6.  
  7. Start the vehicle and check for leaks, repair if necessary.
  8.  

5.3L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
    NOTE
    The intake manifold, throttle body, fuel rail, and injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.

  2.  
  3. Remove the throttle body.
  4.  
  5. Remove the fuel injectors.
  6.  
  7. Remove the brake booster vacuum hose from the intake manifold and the booster check valve.
  8.  
  9. Remove the positive crankcase ventilation (PCV) clean air tube from the air intake duct and valve rocker arm cover.
  10.  
  11. Remove the PCV foul air tube from the intake manifold and valve rocker arm cover.
  12.  
  13. Remove the evaporative emission (EVAP) purge solenoid tube (2) from the solenoid and reposition.
  14.  
  15. Disconnect the following electrical connectors:

    EVAP purge solenoid
     
    Manifold absolute pressure (MAP) sensor
     
    Oil pressure sensor
     
    Valve lifter oil manifold
     

  16.  
  17. Remove the MAP sensor from the intake manifold.
  18.  
  19. Remove the EVAP purge solenoid valve and bracket.
  20.  
  21. Remove the intake manifold bolts.
  22.  
  23. Remove the intake manifold.
  24.  
  25. Remove and discard the intake manifold gaskets.
  26.  

To install:

Click image to see an enlarged view

Fig. Intake manifold bolt torque sequence-5.3L engine

  1. Install the NEW intake manifold gaskets.
  2.  
  3. Install the intake manifold.
  4.  
  5. Apply a band of threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the intake manifold bolts.
  6.  
  7. Install the intake manifold bolts. Tighten the bolts a first pass in sequence to 5 Nm (44 inch lbs.). Tighten the bolts a second pass in sequence to 89 inch lbs. (10 Nm).
  8.  
  9. Install the EVAP purge solenoid bracket and solenoid.
  10.  
  11. Install the MAP sensor to the intake manifold.
  12.  
  13. Connect the following electrical connectors:

    EVAP purge solenoid
     
    MAP sensor
     
    Oil pressure sensor
     
    Valve lifter oil manifold
     

  14.  
  15. Position and install the EVAP purge solenoid tube to the solenoid.
  16.  
  17. Install the PCV foul air tube to the intake manifold and valve rocker arm cover.
  18.  
  19. Install the PCV clean air tube to the air intake duct and valve rocker arm cover.
  20.  
  21. Install the brake booster vacuum hose to the intake manifold and the booster check valve.
  22.  
  23. Install the fuel injectors.
  24.  
  25. Install the throttle body.
  26.  

 
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