1. Disconnect negative battery cable, and drain cooling system. Relieve fuel pressure. See FUEL PRESSURE RELEASE. Remove air intake duct assembly and fuel rail covers. Disconnect throttle and cruise
control cables. Mark and disconnect necessary electrical connectors and vacuum hoses.
2. Remove heater hoses. Remove AIR diverter valve hoses. Disconnect fuel pressure regulator vacuum hose. Remove fuel injectors and fuel rail from intake manifold, and position aside.
3. Remove PCV valve and hose. Remove EGR solenoid bracket and EGR valve. Remove fuel vapor canister purge solenoid bracket and solenoid. Remove AIR pipe from intake manifold and right exhaust manifold.
4. Remove alternator brace. Remove throttle body and gasket. Remove intake manifold and gaskets.
Clean gasket surfaces. Apply 3/16" bead of RTV Sealer (1052289) to front and rear of cylinder block, and run the same bead 1/2" onto each cylinder head. Install gaskets and intake manifold. Tighten bolts and studs to
specification in sequence. See Fig. 1. Refer to TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure. Adjust timing (if necessary) and check for leaks.
Fig. 1: Intake Manifold Bolt Tightening Sequence
Courtesy of GENERAL MOTORS CORP.