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Removal & Installation (8.1L)

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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.
  1. Disconnect the Mass Airflow (MAF) sensor electrical connector and Intake Air Temperature (IAT) sensor electrical connector. Loosen the clamp at the air cleaner. Remove the air cleaner bolts. Remove the air cleaner. Loosen the clamp at the throttle body. Remove the air cleaner duct.
  2. Remove the coolant recovery reservoir bolt. Reposition the coolant recovery reservoir to the side. Remove the engine cover. See ENGINE COVER . Relieve the fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE . Remove the oil fill tube bracket bolt and tube. Remove the Air Conditioning (A/C) compressor bolts.
  3. Disconnect the A/C compressor and A/C high pressure switch electrical connectors. Reposition the A/C compressor. Remove the Exhaust Gas Recirculation (EGR) valve pipe bolts from the EGR valve. Reposition the EGR valve pipe.
  4. Disconnect the following electrical connectors: Purge valve solenoid, ignition coil harness and Engine Coolant Temperature (ECT) sensor. Remove the ECT sensor wire clip from the ignition coil harness. Disconnect the Manifold Absolute Pressure (MAP) sensor and EGR valve electrical connectors. Disconnect the vacuum hose from the rear of the intake manifold. Disconnect the ignition coil, Throttle Position (TP) Sensor and Electronic Throttle Control (ETC) electrical connectors. Remove the passenger rear, and the drivers front and rear harness clip bolts from the top of the intake manifold. Open the passenger front harness clip. Remove the harness from the clip. Reposition the engine wiring harness.
  5. Disconnect the evaporative emission canister tube from the purge solenoid. Disconnect the EVAP canister tube clip from the fuel rail. Disconnect the EVAP canister tube from the canister. Remove the EVAP canister tube. Disconnect the fuel line quick connect fittings. See QUICK CONNECT FITTINGS  in FUEL SYSTEMS.
    6. WARNING: Do not attempt to loosen the manifold by prying under the gasket surface with any tool.
  6. Remove the intake manifold bolts. Remove the intake manifold. Remove and discard the intake manifold side gaskets and the lower intake manifold end seals. The splash shield is reusable. Remove the splash shield. The splash shield is secured using a snap-in fit. Do not distort the splash shield.
  7. If replacement of the intake manifold is required, remove the throttle body and gasket, the fuel pressure regulator vacuum hose, the fuel rail studs and nuts, then the fuel rail and injectors. If replacement of the intake manifold is required, remove the purge solenoid bolt and purge solenoid, the MAP sensor bolt and sensor and the EGR valve. Discard the EGR valve gasket. Inspect the MAP sensor for damage.
  8. If replacement of the intake manifold was required, install a NEW EGR valve gasket and the EGR valve. Lubricate the port of the MAP sensor with clean engine oil. Avoid dipping the sensor port directly into the lubricant or using a solid type of lubricant, as they may block the vacuum port signal. Install the MAP sensor. Apply a very light film of clean engine oil to the purge solenoid seal. Install the purge solenoid install a NEW throttle body gasket and the throttle body.
    9. WARNING: The entire intake manifold tightening sequence must be followed exactly, or an oil leak resulting in engine damage may occur. Ensure the intake manifold is tightened without allowing the intake manifold to shift. The entire intake manifold tightening sequence must be promptly completed due to anaerobic thread adhesive. The final pass of the tightening sequence must be completed before the adhesive starts to cure, or false torque readings and ineffective thread locking may result.
  9. Install the intake manifold splash shield. Ensure the splash shield snap fits between the cylinder heads. Install NEW intake manifold end seals and intake manifold side gaskets. Ensure the intake manifold gasket tabs align with the hole in the head gasket. Ensure the intake manifold gasket tabs align with the slot in the intake manifold end seals. Install the intake manifold. Apply Threadlock (GM 12345382) to a minimum of eight threads of the intake manifold bolts. Install the intake manifold bolts. Tighten the intake manifold bolts in sequence, using four passes. To complete installation, reverse removal procedure. See TORQUE SPECIFICATIONS . Install the engine cover.
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