S10 Pickup, Sonoma 2000-2004

Intake Manifold

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Removal & Installation



2.2L Engine
  1. Remove or disconnect the following:

    Negative battery cable and remove the air cleaner resonator.
     
    Three vacuum hoses from the throttle body
     
    Throttle cable support bracket and the throttle body assembly
     
    Upper fan shroud and disconnect the vacuum brake booster hose, if necessary
     
    Exhaust Gas Recirculation (EGR) pipe-to-manifold bolts and the EGR pipe-to-EGR adapter bolt, and the EGR pipe.
     
    EGR adapter
     
    Idle Air Control (IAC) motor connector
     
    Idle Air Control (IAC) motor
     
    Manifold Absolute Pressure (MAP) sensor connector
     
    Throttle Position (TP) sensor connector
     
    Fuel injector harness connector
     
    Right fender wheelhouse extension
     
    Retainers from the engine harness bracket, the transmission filler tube (if equipped) and the fuel system evaporator pipe
     
    Fuel pipes from the fuel rail
     
    Accelerator cable and if equipped, the cruise control cable
     
    Spark plug wires from the plugs
     
    Spark plug wire harness retainer from the heater hose pipe and set aside the harness
     
    Alternator rear brace by accessing the retaining nuts and bolts through the wheelhouse, if necessary
     
    Engine wiring harness bracket located at the rear of the cylinder head (if necessary), by unfastening the bracket-to-valve cover and bracket-to-cylinder head retainers, then slide the bracket off the bolt at the rear of the cylinder head
     
    Intake manifold bolts
     
    Fuel rail bracket
     
    Intake manifold and gasket

    Click image to see an enlarged view

    Fig. Typical intake manifold mounting-2.2L engine shown

     

  2.  

To install:

  1. Carefully remove all traces of gasket material from the mating surfaces. Check the EGR passage to be sure it is free of excessive carbon deposits and clean, as necessary.
  2.  
  3. Install or connect the following:

    Lower intake manifold using a new gasket, then tighten the retaining bolts to 17 ft. lbs. (24 Nm) using the sequence illustrated

    Click image to see an enlarged view

    Fig. Intake manifold bolt tightening sequence-2.2L engine

     
    Engine wiring harness bracket, if removed. Tighten the bracket-to-valve cover bolts to 88 inch lbs. (10 Nm) and the bracket-to-cylinder head bolt to 18 ft. lbs. (25 Nm).
     
    Generator rear brace, if removed. Tighten the nuts and bolts to 18 ft. lbs. (25 Nm).
     
    Spark plug wire harness and retainer and attach the spark plug wires to the plugs
     
    Throttle body assembly, if removed and the throttle cable support bracket
     
    Three vacuum lines to the throttle body
     
    Accelerator cable and if equipped, the cruise control cable
     
    Fuel lines
     
    Retainers to the engine harness bracket, the transmission filler tube (if equipped) and the fuel system evaporator pipe
     
    IAC motor connector
     
    MAP sensor connector
     
    TP sensor connector
     
    Fuel injector harness connector
     
    Wheelhouse extension
     
    EGR adapter and tighten the retainers to 97 inch lbs. (11 Nm)
     
    EGR pipe to the EGR adapter and tighten the bolt to 18 ft. lbs. (25 Nm)
     
    EGR pipe-to-intake manifold bolts and tighten the bolts to 89 inch lbs. (10 Nm)
     
    Upper fan shroud and the brake booster hose
     
    Air cleaner resonator and connect the negative battery cable.
     

  4.  
  5. Start the engine and check for leaks.
  6.  

4.3L Engines

NOTE
If only the upper intake manifold is being removed, the fuel system pressure does not need to be released. ALWAYS release the pressure before disconnecting any fuel lines.

  1. Remove the engine cover, if equipped
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the engine cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner and air inlet duct
     
    Wiring harness connectors and brackets
     
    Throttle linkage from the upper intake manifold
     
    Ignition coil
     
    Fuel lines and bracket from the rear of the lower intake manifold
     
    Brake booster vacuum hose at the upper intake manifold
     
    Positive Crankcase Ventilation (PCV) hose at the rear of the upper intake manifold
     
    Vacuum hoses from both the front and rear of the upper intake
     
    Purge solenoid and bracket
     
    Upper intake manifold
     
    High Voltage Switch (HVS) assembly
     
    Upper radiator hose at the thermostat housing
     
    Heater hose at the lower intake manifold
     
    Wiring harnesses and brackets.
     
    Automatic transmission dipstick tube
     
    Exhaust Gas Recirculation (EGR) tube, clamp and tube
     
    Air conditioning compressor bracket-to-lower intake manifold pencil brace
     
    Alternator bracket bolts near the thermostat housing
     
    Lower intake manifold
     

  8.  
  9. Insert clean rags into the openings in the cylinder head to prevent dirt and debris from entering the engine.
  10.  
  11. Clean the gasket mounting surfaces. Be sure to inspect the manifold for warpage and/or cracks. If necessary, replace it.

    Click image to see an enlarged view

    Fig. Intake manifold and related components-4.3L engine

  12.  

To install:

  1. Remove the rags from the cylinder heads.
  2.  
  3. Position the gaskets on the cylinder head with the port blocking plates to the rear and the This Side Up stamps facing upward. Then apply a 3 / 16 in. (5mm) bead of RTV sealant on the front and rear of the engine block at the block-to-manifold mating surface. Extend the bead 1 / 2 in. (13mm) up each cylinder head to seal and retain the gaskets.

    Click image to see an enlarged view

    Fig. Lower intake manifold tightening sequence-4.3L engines

  4.  
  5. Install the lower intake manifold. Tighten the bolts in sequence and in 3 steps, as follows:


    1. Step 1: 26 inch lbs. (3 Nm).
    2.  
    3. Step 2: 106 inch lbs. (12 Nm).
    4.  
    5. Step 3: 11 ft. lbs. (15 Nm).
    6.  

  6.  
  7. Install or connect the following:

    Alternator bracket bolt near the thermostat housing
     
    EGR tube, clamp and bolt
     
    Wiring harness to the lower manifold components, including the injector, EGR valve and ECT sensor
     
    Air conditioning compressor bracket-to-the lower intake manifold pencil braces
     
    Transmission oil dipstick tube, if necessary
     
    Fuel supply and return lines to the rear of the lower intake
     

  8.  
  9. Temporarily reattach the negative battery cable, then pressurize the fuel system (by cycling the ignition without starting the engine) and check for leaks.
  10.  
  11. Disconnect the negative battery cable.
  12.  
  13. Install or connect the following:

    Heater hose to the lower intake
     
    Upper radiator hose to the thermostat housing
     
    Vacuum hoses to the upper and lower intake manifold
     
    New upper intake manifold gasket, making sure the green sealing lines are facing upward
     
    Upper intake manifold being careful not to pinch the fuel injector wires between the manifolds
     
    Manifold retainers. Tighten them to 88 inch lbs. (10 Nm) using two passes.
     
    Purge solenoid and bracket
     
    Brake booster vacuum hose at the upper intake manifold.
     
    PCV hose to the rear of the upper intake manifold
     
    Vacuum hoses to both the front and rear of the manifold assembly
     
    Throttle linkage to the upper intake
     
    Ignition coil
     
    Wiring to the upper intake components including the TP sensor, IAC motor, MAP sensor and the IMTV.
     
    Plastic cover
     
    Air cleaner and air inlet duct
     
    Negative battery cable
     

  14.  
  15. Refill the engine cooling system.
  16.  

 
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