GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Oldsmobile 🢒 2001 🢒 Intrigue 🢒 Engine 🢒 Engine Mechanical - 3.5L 🢒 Intake Manifold Replacement

Removal Procedure
  1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Remove the throttle body air inlet duct from the throttle body. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls-3.5L.
  3. Partially drain the engine coolant from the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.

    4. Object Number: 289500 Size: SH
  4. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
  5. Disconnect the throttle and cruise cables with the mounting bracket from the throttle body. Refer to the following procedures:
    6. •  Accelerator Control Cable Replacement in Engine Controls-3.5L
    •  Accelerator Control Cable Bracket Replacement in Engine Controls-3.5L
  6. Remove the throttle body coolant hoses from the throttle body. Refer to Throttle Body Heater Inlet Hose Replacement and Throttle Body Heater Outlet Hose Replacement in Engine Cooling.

    7. Object Number: 293967 Size: SH
  7. Disconnect the fuel lines from the fuel rail. Refer to Fuel Pressure Relief and Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service in Engine Controls-3.5L.

    8. Object Number: 293966 Size: SH
  8. Disconnect the fuel vapor line from the EVAP canister purge solenoid.

    9. Object Number: 293968 Size: SH
  9. Remove the brake booster vacuum hose from the brake booster.
  10. Remove the A/C vacuum hose from the intake manifold.
  11. Remove the surge tank inlet pipe retainer from the fuel injector rail.
  12. Disconnect the engine wiring harness connectors from the following components:
    13. • Fuel injectors
    • Throttle position (TP) sensor
    • Idle air control (IAC) valve
    • EVAP canister purge solenoid
    • Manifold absolute pressure (MAP) sensor
  13. Remove the engine wiring harness channel bolts from the camshaft covers.
  14. Remove and set aside the engine wiring harness and channel.

    15. Object Number: 235254 Size: SH
  15. Remove the fuel pressure regulator vacuum tube (1) from the regulator (2) and the throttle body (3).

    16. Object Number: 679777 Size: SH
  16. Disconnect and remove the PCV valve and both feed tubes (1, 2) from the camshaft covers and intake manifold.

    17. Object Number: 576171 Size: SH
  17. Remove the EGR valve outlet pipe retaining bolts from the intake manifold and the water crossover.
  18. Remove the EGR valve outlet pipe.

    19. Object Number: 234312 Size: SH
  19. Disconnect the 4 fuel rail snap-lock retainers by pushing toward the camshaft covers and lifting.
  20. Remove the fuel rail (1) and fuel injectors (2) as an assembly and store in a clean, secure location away from any heat sources.

    21. Object Number: 520848 Size: SH
  21. Remove the intake manifold bolts.

    22. Object Number: 287926 Size: SH
  22. Remove the throttle body coolant hose from the water crossover feed tube (1).

    23. Object Number: 679782 Size: SH
  23. Remove the intake manifold.

    24. Important: If you are replacing the intake manifold perform the following steps.

  24. Disassemble the intake manifold. Refer to Intake Manifold Disassemble in Engine Mechanical - 3.5L - Unit Repair.
  25. Clean and inspect the intake manifold. Refer to Intake Manifold Cleaning and Inspection in Engine Mechanical - 3.5L - Unit Repair.
  26. Assemble the intake manifold. Refer to Intake Manifold Assemble in Engine Mechanical - 3.5L - Unit Repair.

Installation Procedure

    Object Number: 679782 Size: SH
  1. Install the intake manifold.

    2. Object Number: 287926 Size: SH
  2. Install the throttle body heater hose to the water crossover feed tube (1).
  3. Install the hose clamp.

    4. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.


    Object Number: 520848 Size: SH
  4. Install the intake manifold bolts.

    5. Important: Tighten the intake manifold bolts in circular pattern starting from the center and moving outward.

    Tighten
    Tighten the intake manifold bolts to 7 N·m (62 lb in).


    Object Number: 234312 Size: SH
  5. Inspect the fuel injector O-rings (2) for misalignment or damage. Replace the O-rings if necessary.

    6. Important: Do not apply excessive pressure to the fuel rail when installing. If excessive pressure is needed to install the fuel rail then misalignment of a fuel injector could be the concern and using excessive pressure will only cause damage to the seal or intake manifold.

  6. Install the fuel rail (1) and fuel injectors (2) by aligning the fuel injectors with their respective ports and pressing the four fuel rail snap-lock connectors into the intake manifold until they lock in place.

    7. Object Number: 576171 Size: SH
  7. Install the EGR outlet pipe.
  8. Install the EGR outlet pipe to intake manifold bolt.

    9. Tighten
    Tighten the EGR outlet pipe to intake manifold bolt to 10 N·m (89 lb in).

  9. Install the EGR outlet pipe to water crossover bolt.

    10. Tighten
    Tighten the EGR outlet pipe to water crossover bolt to 24 N·m (18 lb ft).


    Object Number: 679777 Size: SH
  10. Install the PCV valve and connect both feed tubes (1, 2) to the camshaft covers and intake manifold.

    11. Object Number: 293968 Size: SH
  11. Install the brake booster vacuum hose to the brake booster.

    12. Object Number: 235254 Size: SH
  12. Install the fuel pressure regulator vacuum tube (1) to the regulator (2) and the throttle body (3).
  13. Install the A/C vacuum hose to the intake manifold.
  14. Install the engine wiring harness and channel.
  15. Install the engine wiring harness channel bolts to the camshaft covers.

    16. Tighten
    Tighten the engine wiring harness channel bolts to 10 N·m (89 lb in).

  16. Connect the surge tank inlet pipe retainer to the fuel injector rail.
  17. Connect the engine wiring harness connectors to the following components:
    18. • Throttle position (TP) sensor
    • Idle air control (IAC) valve
    • EVAP canister purge solenoid
    • Manifold absolute pressure (MAP) sensor
    • Fuel injectors
  18. Connect the throttle body coolant hoses to the throttle body. Refer to Throttle Body Heater Inlet Hose Replacement and Throttle Body Heater Outlet Hose Replacement in Engine Cooling.
  19. Connect the throttle and cruise control cables with the mounting bracket to the throttle body. Refer to the following procedures:
    20. •  Accelerator Control Cable Replacement in Engine Controls-3.5L
    •  Cruise Control Cable Replacement in Engine Controls-3.5L

    Object Number: 293967 Size: SH
  20. Connect the fuel lines to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service in Engine Controls-3.5L.

    21. Object Number: 293966 Size: SH
  21. Connect the fuel vapor line to the EVAP canister purge solenoid.

    22. Object Number: 289500 Size: SH
  22. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
  23. Install the throttle body air inlet duct to the throttle body. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls-3.5L.
  24. Fill the cooling system with engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
  25. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.