Disconnect negative battery cable.
Remove fuel injector sight shield.
Drain cooling system.
Remove air cleaner ducts.
Remove accelerator and cruise control cables with bracket from throttle body.
Remove front spark plug wires.
Disconnect harness connectors, vacuum hoses and coolant hoses from throttle body.
Remove ignition coil bracket with coils and canister purge solenoid.
Remove manifold air pressure (MAP) sensor. Disconnect and remove emission control vacuum harness.
Remove EGR valve and generator front and side brackets.
Remove upper intake manifold retaining bolts. Remove upper intake manifold.
VALVE COVERS
Removal (Left)
Remove front spark plug wires.
Remove A/T vacuum modulator pipe (if equipped). Remove right engine strut at engine.
Remove PCV valve.
Remove valve cover retaining bolts.
Remove valve cover and gasket.
Removal (Right)
Remove accessory drive belt.
Remove generator braces.
Remove generator and bracket.
Remove rear spark plug wires.
Remove ignition coil bracket with coils and canister purge solenoid attached.
Remove vacuum hose from air duct at right valve cover.
Remove valve cover retaining bolts.
Remove valve cover and gasket.
LOWER INTAKE MANIFOLD
Disconnect harness connectors from intake manifold components.
Release fuel pressure.
Disconnect fuel lines from rail.
Remove fuel rail.
Unbolt power steering pump from front cover and position aside.
Disconnect upper radiator hose, heater hoses and thermostat bypass hose from lower intake manifold. Remove lower intake manifold retaining bolts. Remove lower intake manifold.
Loosen rocker arms and remove push rods to remove lower intake manifold gaskets
When replacing intake manifold gasket, a revised intake manifold gasket has been introduced by manufacturer. This new design gasket helps resolve issues related to intake manifold oil/coolant leaks. The gasket requires a revised torque specification and procedure in addition to the use of NEW revised intake manifold bolts. Please review TSB ENGINE OIL OR COOLANT LEAK (INSTALL NEW INTAKE MANIFOLD GASKET) for complete information.
NOTE:All gasket-mating surfaces need to be free of oil, and foreign material.
Clean all gasket mating surfaces.
Install lower intake manifold gaskets.
With the gaskets in place, apply a 0.31-0.39" (8-10 mm) drop of GM Â RTV sealer (12346286 US; 10953472 Canada) or equivalent to the 4 corners of the intake manifold-to-block joint. Connect the drops at both ends on the ridge where the front and rear of lower intake manifold contacts the block with a bead of RTV sealer that is 0.31-0.39" (8-10 mm) wide and 0.12-0.20" (3.0-5.0 mm) thick.
Install push rods in original position and tighten rocker arms to specification.
Install lower intake manifold.
Apply sealant (12345282) to bolt threads if reusing original bolts.
Tighten bolts to specification.
To complete installation, reverse removal procedure.
NOTE:An oil leak may result if vertical bolts are not tightened before diagonal bolts.
Tuesday, September 8th, 2009 AT 9:24 PM