GMC 12699182 Manifold Assembly, Upr Int

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To begin the process of removing the manifold, disconnect the cable from the negative battery terminal. The engine top cover and the air outlet tube from the air filter housing should be removed for 2008 and earlier models. Relocate the PCV tube from the air filter inlet and cut off power to intake manifold tuning valve, throttle body and Manifold Absolute Pressure (MAP) sensor by unplugging their connectors. Detach brake booster vacuum hose and wiring from throttle body. Disconnect PCV tube from intake manifold and remove quick-connect fitting at EVAP canister purge solenoid tube. Set EVAP tube aside; also, unbolt fasteners from engine wiring harness. Ensure all interfering wiring and hoses are disconnected and moved clear of the intake manifold. Remove six mounting bolts off upper intake manifold top and take out both manifolds along with upper intake gasket as a single unit. For lower intake manifold, first relieve fuel system pressure then disconnect fuel feed line from fuel rail. Fuel rail comes out first followed by lower intake manifold mounting bolts that enable lifting off of manifolds themselves. Take away oil filler cap so that engine cover is lifted away too. Discard air filter housing after disconnecting its housing outlet duct too. Disconnect brake booster hose vacuum and PCV hose from the assembly's other side, which are very easy to remove given their visible positions on either side of the assembly front end under consideration. The electrical connectors to EVAP purge solenoid valve and throttle body will need to be unclasped in due course just like every other electrical connector on/around an automobile's intake system emanating from power distribution center (PDC) to ECU/PCM connection point(s), which is located at backside firewall area next to dash panel assembly near steering column support bracket mount location points behind instrument panel (IP) above floor console or beneath dashboard cover trim piece where they usually reside such as glove compartment box area depending upon particular make/model/year configuration employed by vehicle's builder/designer/engineer(s). After intake manifold sound insulator removal (if so equipped), remove intake manifold bolts, throw away intake manifold gasket and clean all old gasket material. Chase threads in bolt holes using a tap; then, attach new gaskets to cylinder heads. Install lower intake manifold for which fuel injectors and rail are replaced. Put on new gaskets on top of lower intake manifold and replace upper one as well. Tighten bolts evenly. When it comes to 2009 and later models, crisscross tightened bolts will secure the newly installed manifold in place before reversing the entire process performed during dismounting of old assembly piece.

Disconnect the cable from the negative terminal of the battery and remove the engine cover. Disconnect the brake booster vacuum tube from the intake manifold, then disconnect the front spark plug wires from the spark plugs and the bracket. Remove the ignition coil along with its bracket, positioning it out of the way, and remove the air intake duct. Unbolt the heater outlet tube from the top of the engine and move it aside without disconnecting the heater hoses. Remove the EGR tube and the PCV tube, then unscrew the alternator mounting bolt closest to the intake manifold, allowing it to remain in place but pulled out about an inch. Remove the alternator bracket into which the mounting bolt was threaded, loosening the upper alternator mounting bolt and sliding it out far enough to remove this bracket. Remove the spark plug wire retainer from the top of the intake manifold, disconnect the MAP sensor, and any remaining interfering components. Loosen the upper intake manifold bolts gradually, starting with the outer bolts and working towards the inner bolts, then remove the upper intake manifold with the throttle body attached. Clean the mounting surfaces of the lower and upper intake manifolds with brake system cleaner, removing all traces of old gasket material or sealant. Install the new gaskets over the lower intake manifold, then install the upper intake manifold onto the lower intake manifold, tightening the bolts gradually, starting with the inner bolts and working towards the outer bolts, to the specified torque. Drain the cooling system and relieve the fuel system pressure before removing the upper intake manifold. Disconnect the heater core inlet hose from its tube at the engine, unbolt the tube, pull it out of the socket, and remove it. Remove the upper radiator bracket from the radiator, the radiator inlet hose, and the fuel rail. Remove the valve covers, loosen the rocker arm bolts, rotate the rocker arms out of the way, and remove the pushrods that go through the manifold gaskets. Loosen the manifold mounting bolts/nuts in 1/4-turn increments until they can be removed by hand. The manifold may be stuck to the cylinder heads, requiring force to break the gasket seal; pry the manifold loose at a casting boss, avoiding prying between the gasket surfaces to prevent damage. Lift the old gaskets off, use a gasket scraper to remove all traces of sealant and old gasket material, and clean the mating surfaces with brake system cleaner. Ensure the mating surfaces of the cylinder heads, block, coolant crossover housing, and manifold are perfectly clean when the manifold is installed. Use a tap of the correct size to chase the threads in the bolt holes if necessary, then use compressed air to remove debris from the holes, wearing safety glasses for protection. Place the intake manifold gaskets in position on the heads, install the push rods and rocker arms, and apply a 3/16-inch bead of RTV sealant to the front and rear ridges of the engine block between the heads, as well as to the end ridges between the cylinder heads. Carefully lower the manifold into place and install the mounting bolts/nuts finger tight, coating the bolt threads with thread-locking liquid before installation. Tighten the four vertical bolts at the center of the manifold in the recommended tightening sequence to the specified torque, followed by the four angled bolts at the ends of the manifold. Install the remaining components in the reverse order of removal, refill the cooling system, start the engine, and check for leaks.

Disconnect the cable from the negative terminal of the battery and remove the engine cover. Disconnect the brake booster vacuum tube from the intake manifold, then disconnect the front spark plug wires from the spark plugs and the bracket. Remove the ignition coil along with its bracket, positioning it out of the way, and remove the air intake duct. Unbolt the heater outlet tube from the top of the engine and move it aside without disconnecting the heater hoses. Remove the EGR tube and the PCV tube, then unscrew the alternator mounting bolt closest to the intake manifold, allowing it to remain in place but pulled out about an inch. Remove the alternator bracket into which the mounting bolt was threaded, loosening the upper alternator mounting bolt and sliding it out far enough to remove this bracket. Remove the spark plug wire retainer from the top of the intake manifold, disconnect the MAP sensor, and any remaining interfering components. Loosen the upper intake manifold bolts gradually, starting with the outer bolts and working towards the inner bolts, then remove the upper intake manifold with the throttle body attached. Clean the mounting surfaces of the lower and upper intake manifolds with brake system cleaner, removing all traces of old gasket material or sealant. Install the new gaskets over the lower intake manifold, then install the upper intake manifold onto the lower intake manifold, tightening the bolts gradually, starting with the inner bolts and working towards the outer bolts, to the specified torque. Drain the cooling system and relieve the fuel system pressure before removing the upper intake manifold. Disconnect the heater core inlet hose from its tube at the engine, unbolt the tube, pull it out of the socket, and remove it. Remove the upper radiator bracket from the radiator, the radiator inlet hose, and the fuel rail. Remove the valve covers, loosen the rocker arm bolts, rotate the rocker arms out of the way, and remove the pushrods that go through the manifold gaskets. Loosen the manifold mounting bolts/nuts in 1/4-turn increments until they can be removed by hand. The manifold may be stuck to the cylinder heads, requiring force to break the gasket seal; pry the manifold loose at a casting boss, avoiding prying between the gasket surfaces to prevent damage. Lift the old gaskets off, use a gasket scraper to remove all traces of sealant and old gasket material, and clean the mating surfaces with brake system cleaner. Ensure the mating surfaces of the cylinder heads, block, coolant crossover housing, and manifold are perfectly clean when the manifold is installed. Use a tap of the correct size to chase the threads in the bolt holes if necessary, then use compressed air to remove debris from the holes, wearing safety glasses for protection. Place the intake manifold gaskets in position on the heads, install the push rods and rocker arms, and apply a 3/16-inch bead of RTV sealant to the front and rear ridges of the engine block between the heads, as well as to the end ridges between the cylinder heads. Carefully lower the manifold into place and install the mounting bolts/nuts finger tight, coating the bolt threads with thread-locking liquid before installation. Tighten the four vertical bolts at the center of the manifold in the recommended tightening sequence to the specified torque, followed by the four angled bolts at the ends of the manifold. Install the remaining components in the reverse order of removal, refill the cooling system, start the engine, and check for leaks.

To begin the process of removing the manifold, disconnect the cable from the negative battery terminal. The engine top cover and the air outlet tube from the air filter housing should be removed for 2008 and earlier models. Relocate the PCV tube from the air filter inlet and cut off power to intake manifold tuning valve, throttle body and Manifold Absolute Pressure (MAP) sensor by unplugging their connectors. Detach brake booster vacuum hose and wiring from throttle body. Disconnect PCV tube from intake manifold and remove quick-connect fitting at EVAP canister purge solenoid tube. Set EVAP tube aside; also, unbolt fasteners from engine wiring harness. Ensure all interfering wiring and hoses are disconnected and moved clear of the intake manifold. Remove six mounting bolts off upper intake manifold top and take out both manifolds along with upper intake gasket as a single unit. For lower intake manifold, first relieve fuel system pressure then disconnect fuel feed line from fuel rail. Fuel rail comes out first followed by lower intake manifold mounting bolts that enable lifting off of manifolds themselves. Take away oil filler cap so that engine cover is lifted away too. Discard air filter housing after disconnecting its housing outlet duct too. Disconnect brake booster hose vacuum and PCV hose from the assembly's other side, which are very easy to remove given their visible positions on either side of the assembly front end under consideration. The electrical connectors to EVAP purge solenoid valve and throttle body will need to be unclasped in due course just like every other electrical connector on/around an automobile's intake system emanating from power distribution center (PDC) to ECU/PCM connection point(s), which is located at backside firewall area next to dash panel assembly near steering column support bracket mount location points behind instrument panel (IP) above floor console or beneath dashboard cover trim piece where they usually reside such as glove compartment box area depending upon particular make/model/year configuration employed by vehicle's builder/designer/engineer(s). After intake manifold sound insulator removal (if so equipped), remove intake manifold bolts, throw away intake manifold gasket and clean all old gasket material. Chase threads in bolt holes using a tap; then, attach new gaskets to cylinder heads. Install lower intake manifold for which fuel injectors and rail are replaced. Put on new gaskets on top of lower intake manifold and replace upper one as well. Tighten bolts evenly. When it comes to 2009 and later models, crisscross tightened bolts will secure the newly installed manifold in place before reversing the entire process performed during dismounting of old assembly piece.

To begin the process of removing the manifold, disconnect the cable from the negative battery terminal. The engine top cover and the air outlet tube from the air filter housing should be removed for 2008 and earlier models. Relocate the PCV tube from the air filter inlet and cut off power to intake manifold tuning valve, throttle body and Manifold Absolute Pressure (MAP) sensor by unplugging their connectors. Detach brake booster vacuum hose and wiring from throttle body. Disconnect PCV tube from intake manifold and remove quick-connect fitting at EVAP canister purge solenoid tube. Set EVAP tube aside; also, unbolt fasteners from engine wiring harness. Ensure all interfering wiring and hoses are disconnected and moved clear of the intake manifold. Remove six mounting bolts off upper intake manifold top and take out both manifolds along with upper intake gasket as a single unit. For lower intake manifold, first relieve fuel system pressure then disconnect fuel feed line from fuel rail. Fuel rail comes out first followed by lower intake manifold mounting bolts that enable lifting off of manifolds themselves. Take away oil filler cap so that engine cover is lifted away too. Discard air filter housing after disconnecting its housing outlet duct too. Disconnect brake booster hose vacuum and PCV hose from the assembly's other side, which are very easy to remove given their visible positions on either side of the assembly front end under consideration. The electrical connectors to EVAP purge solenoid valve and throttle body will need to be unclasped in due course just like every other electrical connector on/around an automobile's intake system emanating from power distribution center (PDC) to ECU/PCM connection point(s), which is located at backside firewall area next to dash panel assembly near steering column support bracket mount location points behind instrument panel (IP) above floor console or beneath dashboard cover trim piece where they usually reside such as glove compartment box area depending upon particular make/model/year configuration employed by vehicle's builder/designer/engineer(s). After intake manifold sound insulator removal (if so equipped), remove intake manifold bolts, throw away intake manifold gasket and clean all old gasket material. Chase threads in bolt holes using a tap; then, attach new gaskets to cylinder heads. Install lower intake manifold for which fuel injectors and rail are replaced. Put on new gaskets on top of lower intake manifold and replace upper one as well. Tighten bolts evenly. When it comes to 2009 and later models, crisscross tightened bolts will secure the newly installed manifold in place before reversing the entire process performed during dismounting of old assembly piece.

Disconnect the PCV tube from the intake manifold and the quick-connect fitting at the tube from the EVAP canister purge solenoid, then move the EVAP tube aside. Remove the ECM bracket without disconnecting the connectors and place it out of the way, followed by disconnecting the fuel injector electrical connectors and moving them aside.

Install new gaskets if necessary, ensuring the intake manifold gaskets are in perfect condition and the mating surfaces are clean.

Proceed to remove the intake manifold insulator fasteners and insulator, followed by the intake manifold mounting fasteners, noting the locations of the stud bolts, and finally remove the intake manifold from the cylinder head.

For the lower intake manifold, disconnect the fuel feed line from the fuel rail, then remove the fuel rail and injectors, followed by removing the lower intake manifold mounting bolts and lifting off the manifold.