H3 2006

Intake Manifold

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Removal & Installation



3.5L & 3.7L Engines

Specific to:

Hummer H3 2006-2010

  1. Remove the throttle body.
  2.  
  3. Remove the battery box.
  4.  
  5. Remove the oil level indicator and tube.
  6.  
  7. Disconnect the brake booster hose from the brake booster.
  8.  
  9. Disconnect the engine wiring harness electrical connector from the Manifold Absolute Pressure (MAP) sensor.
  10.  
  11. Disconnect the engine wiring harness retainer from the intake manifold.
  12.  
  13. Disconnect the Positive Crankcase Ventilation (PCV) dirty air tube from the camshaft cover.
  14.  
  15. Remove the alternator.

    Click image to see an enlarged view

    Fig. Disconnect components

  16.  
  17. Disconnect the engine wiring harness retainer from the intake manifold.

    Click image to see an enlarged view

    Fig. Disconnect the engine wiring harness retainer (1) from the intake manifold (2)

  18.  
  19. Remove the upper 2 bolts securing the engine wiring harness bracket to the intake manifold.
  20.  
  21. Raise and support the vehicle only high enough to access the remaining components through the wheelhouse.
  22.  
  23. Remove the left front wheel.
  24.  
  25. Remove the left front wheelhouse liner.
  26.  
  27. Disconnect the following wiring harness retainers from the engine wiring harness bracket:

    The battery cable
     
    The engine
     
    The MAP sensor

    Click image to see an enlarged view

    Fig. Wiring harness retainers

     

  28.  
  29. Remove the remaining engine wiring harness bracket lower bolt.
  30.  
  31. Remove the bracket from the engine compartment through the wheelhouse opening.
  32.  
  33. Remove the intake manifold bolts.
  34.  
  35. Lower the vehicle.
  36.  
  37. Remove the intake manifold from the cylinder head.

    Click image to see an enlarged view

    Fig. Remove the intake manifold from the cylinder head

  38.  
  39. Remove the seal from the intake manifold. Discard the seal.
  40.  
  41. Mask off the open ports to the cylinder head, in order to prevent foreign objects from entering the engine.
  42.  

To install:

  1. Remove the masking from the cylinder head and ensure the sealing surface is clean and dry.
  2.  
  3. Install a NEW seal into the intake manifold groove.
  4.  
  5. Position the intake manifold to the cylinder head.
  6.  
  7. Raise and support the vehicle only high enough to access the following components through the wheelhouse:

    The intake manifold bolts
     
    The engine wiring harness bracket bolts
     
    The wiring harnesses
     

  8.  
  9. Install the intake manifold bolts and tighten from the inside working outward to 89 inch lbs. (10 Nm).
  10.  
  11. Position the engine wiring harness bracket to the engine.
  12.  
  13. Install the engine wiring harness bracket bolts and tighten to 89 inch lbs. (10 Nm).
  14.  
  15. Secure the following engine wiring harness retainers to the bracket:

    The battery cable
     
    The engine
     
    The MAP sensor
     

  16.  
  17. Install the left front wheelhouse liner.
  18.  
  19. Install the left front wheel.
  20.  
  21. Lower the vehicle.
  22.  
  23. Connect the engine wiring harness retainer to the intake manifold.
  24.  
  25. Install the alternator.
  26.  
  27. Connect the PCV dirty air tube to the camshaft cover.
  28.  
  29. Connect the engine wiring harness retainer to the intake manifold.
  30.  
  31. Connect the engine wiring harness electrical connector to the MAP sensor.
  32.  
  33. Connect the brake booster hose to the brake booster.
  34.  
  35. Install the oil level indicator and tube.
  36.  
  37. Install the battery box.
  38.  
  39. Install the throttle body.
  40.  

5.3L Engine

Specific to:

Hummer H3 2006-2010

  1. Remove the air cleaner outlet duct.
  2.  
  3. Remove the alternator.
  4.  
  5. Remove the engine harness retainer nut.
  6.  
  7. Remove the engine harness retainer from the stud and locator pin.
  8.  
  9. Disconnect the engine harness electrical connector from the Evaporative Emission (EVAP) canister purge solenoid.
  10.  
  11. Disconnect the engine wiring harness electrical connector from the Manifold Absolute Pressure (MAP) sensor.
  12.  
  13. Disconnect the engine harness electrical connector from the ignition coil harness electrical connector.
  14.  
  15. Disconnect the engine harness electrical connectors from the left side fuel injectors.
  16.  
  17. Remove the engine harness clip from the ignition coil bracket stud.
  18.  
  19. Disconnect the engine harness electrical connector from the ignition coil harness electrical connector.
  20.  
  21. Disconnect the engine harness electrical connector from the throttle actuator.
  22.  
  23. Remove the engine harness clip from the ignition coil bracket stud.
  24.  
  25. Disconnect the engine harness electrical connectors from the right side fuel injectors.
  26.  
  27. Remove the engine harness clips.
  28.  
  29. Disconnect the engine harness electrical connector from the Engine Coolant Temperature (ECT) sensor.
  30.  
  31. Gather the engine harness branches and tie the harness up out of the way to the front of the engine compartment.
  32.  
  33. Disconnect the engine oil pressure sensor electrical connector.

    Click image to see an enlarged view

    Fig. Engine oil pressure sensor location (1)

  34.  
  35. Reposition the brake booster vacuum hose clamp at the booster.
  36.  
  37. Remove the brake booster vacuum hose from the booster fitting.
  38.  
  39. Secure the brake booster vacuum hose to the intake manifold.
  40.  
  41. Disconnect the EVAP canister purge tube quick connect fitting from the EVAP canister purge solenoid.
  42.  
  43. Disconnect the fuel feed line quick connect fitting from the fuel rail.

    Click image to see an enlarged view

    Fig. EVAP connections

  44.  
  45. Remove the Positive Crankcase Ventilation (PCV) hose from the intake manifold fitting.
  46.  
  47. Position the hose out of the way.
  48.  
  49. Loosen the intake manifold bolts (512).
    NOTE
    The aid of an assistant may be helpful in holding the engine harness up out of the way so the upper intake manifold cover does not get caught against the engine harness.

  50.  
  51. Remove the intake manifold (500).

    Click image to see an enlarged view

    Fig. Intake manifold bolt location

  52.  
  53. Cover the cylinder head passages in order to prevent dirt or debris from entering the passages.
  54.  
  55. Remove and discard the intake manifold gaskets.
  56.  
  57. If replacing the intake manifold, perform the following steps, otherwise proceed to step 21 of the installation procedure.
  58.  
  59. Place the intake manifold on a clean work surface.
  60.  
  61. Reposition the brake booster vacuum hose clamp at the intake manifold.
  62.  
  63. Remove the brake booster vacuum hose from the intake manifold nipple.
  64.  
  65. Remove the upper intake manifold cover nut.
  66.  
  67. Remove the upper intake manifold cover.
  68.  
  69. Remove the MAP sensor retainer.
  70.  
  71. Remove the MAP sensor.

    Click image to see an enlarged view

    Fig. MAP sensor location

  72.  
  73. Disconnect the EVAP tube quick connect fitting at the intake manifold.
  74.  
  75. Disengage the retainer securing the EVAP canister purge solenoid to the fuel rail.
  76.  
  77. Remove the EVAP tube and purge solenoid.

    Click image to see an enlarged view

    Fig. EVAP purge solenoid location

  78.  
  79. Remove the throttle body bolts/nuts.
  80.  
  81. Remove the throttle body.
  82.  
  83. Remove and discard the throttle body gasket.

    Click image to see an enlarged view

    Fig. Throttle body

  84.  
  85. Remove the fuel rail bolts.
    NOTE
    Lift evenly on both sides of the fuel rail until all injectors are removed from their bores.

  86.  
  87. Remove the fuel rail.
  88.  
  89. Remove and discard the fuel injector lower O-ring seals.
    NOTE
    Evenly push in the RED collar in order to remove the nipple.



    Click image to see an enlarged view

    Fig. Fuel rail bolt locations

  90.  
  91. Remove the brake booster vacuum hose nipple.
  92.  

To install:

  1. If the intake manifold was replaced perform the following steps, otherwise proceed to step 21.
    NOTE
    Evenly push in the RED collar in order to install the nipple.

  2.  
  3. Install the brake booster vacuum hose nipple to the NEW intake manifold.
  4.  
  5. Install NEW fuel injector lower O-ring seals onto the injectors.
  6.  
  7. Lubricate the NEW O-ring seals with clean engine oil.
    NOTE
    Push down firmly on both sides of the rail until all the injectors have been seated into their bores.

  8.  
  9. Install the fuel rail.
  10.  
  11. Install the fuel rail bolts and tighten to 89 inch lbs. (10 Nm).
  12.  
  13. Install a NEW throttle body gasket to the intake manifold.
  14.  
  15. Install the throttle body.
  16.  
  17. Install the throttle body bolts/nuts and tighten to 89 inch lbs. (10 Nm).
  18.  
  19. Install the EVAP tube and purge solenoid.
  20.  
  21. Install the EVAP canister purge solenoid to the fuel rail bracket and engage the retainer.
  22.  
  23. Connect the EVAP tube quick connect fitting at the intake manifold.
  24.  
  25. Lubricate the MAP sensor seal with clean engine oil.
  26.  
  27. Install the MAP sensor.
  28.  
  29. Install the MAP sensor retainer.
  30.  
  31. Install the upper intake manifold cover.
  32.  
  33. Install the upper intake manifold cover nut until snug
  34.  
  35. Install the brake booster vacuum hose to the intake manifold nipple.
  36.  
  37. Position the brake booster vacuum hose clamp at the intake manifold.
  38.  
  39. Secure the brake booster vacuum hose to the intake manifold.
  40.  
  41. Install NEW intake manifold gaskets to the intake manifold.
  42.  
  43. Remove the covers from the cylinder head passages.
  44.  
  45. Install the intake manifold.
    NOTE
    The aid of an assistant may be helpful in holding the engine harness up out of the way so the upper intake manifold cover does not get caught against the engine harness.

  46.  
  47. Tighten the intake manifold bolts until snug.
  48.  
  49. Tighten the intake manifold bolts to specifications:
    1. Tighten the bolts a first pass in the sequence shown to 44 inch lbs. (5 Nm).
    2.  
    3. Tighten the bolts a final pass in the sequence shown to 89 inch lbs. (10 Nm).

      Click image to see an enlarged view

      Fig. Intake manifold bolt tightening sequence

    4.  

  50.  
  51. Position and install the PCV hose to the intake manifold fitting.
  52.  
  53. Connect the fuel feed line quick connect fitting to the fuel rail.
  54.  
  55. Connect the EVAP canister purge tube quick connect fitting to the EVAP canister purge solenoid.
  56.  
  57. Unsecure the brake booster vacuum hose from the intake manifold.
  58.  
  59. Install the brake booster vacuum hose to the booster fitting.
  60.  
  61. Position the brake booster vacuum hose clamp at the booster.
  62.  
  63. Connect the engine oil pressure sensor electrical connector.
  64.  
  65. Untie the engine harness branches from the front of the engine compartment and position over the engine.
  66.  
  67. Connect the engine harness electrical connector to the ECT sensor.
  68.  
  69. Position the engine harness clips to the bracket.
  70.  
  71. Connect the engine harness electrical connectors to the right side fuel injectors.
  72.  
  73. Install the engine harness clip to the ignition coil bracket stud.
  74.  
  75. Connect the engine harness electrical connector to the throttle actuator.
  76.  
  77. Connect the engine harness electrical connector to the ignition coil harness electrical connector.
  78.  
  79. Install the engine harness clip to the ignition coil bracket stud.
  80.  
  81. Connect the engine harness electrical connectors to the left side fuel injectors.
  82.  
  83. Connect the engine harness electrical connector to the ignition coil harness electrical connector.
  84.  
  85. Install the CPA retainer.
  86.  
  87. Connect the engine wiring harness electrical connector to the MAP sensor.
  88.  
  89. Connect the engine harness electrical connector to the EVAP canister purge solenoid.
  90.  
  91. Install the engine harness retainer to the stud and locator pin.
  92.  
  93. Install the engine harness retainer nut and tighten to 44 inch lbs. (5 Nm).
  94.  
  95. Install the alternator.
  96.  
  97. Install the air cleaner outlet duct.
  98.  

 
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