GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2004 🢒 Malibu 🢒 Engine 🢒 Engine Mechanical - 3.5L (LX9) 🢒 Upper Intake Manifold Replacement

Removal Procedure

    Object Number: 909586 Size: SH
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Remove the vacuum hoses from the following:
    3. • Evaporative emissions (EVAP) canister purge valve
    • Manifold vacuum source
    • Brake booster
    • Heater and air conditioning source
  3. Disconnect the electrical connectors from the following:
    4. • Exhaust gas recirculation (EGR) valve
    • Mass air flow (MAF) sensor
    • Intake air temperature (IAT) sensor
    • Electronic throttle control
    • EVAP canister purge valve
  4. Remove the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls - 3.5L.
  5. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  6. Remove the left side spark plug wires from the spark plugs. Refer to Spark Plug Wire Replacement in Engine Controls - 3.5L.
  7. Remove the following wiring harnesses from the retainers:
    8. • Camshaft position (CMP) sensor wiring harness
    • Left side spark plug wire harness
    • Engine wiring harness

    Object Number: 1239040 Size: SH
  8. Remove the ignition coil bracket with the coils. Refer to Ignition Control Module Replacement in Engine Controls - 3.5L.
  9. Remove the EVAP canister purge valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement in Engine Controls - 3.5L.
  10. Remove the manifold absolute pressure (MAP) sensor and the bracket. Refer to Manifold Absolute Pressure Sensor Replacement in Engine Controls - 3.5L.
  11. Remove the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement in Engine Controls - 3.5L.
  12. Remove the upper intake manifold bolts and the stud.
  13. Remove the upper intake manifold.
  14. Remove the upper intake manifold gaskets.

    15. Object Number: 1239002 Size: SH
  15. If replacing the upper intake manifold, remove the throttle body. Refer to Throttle Body Assembly Replacement in Engine Controls - 3.5L.
  16. Clean the upper intake gasket mating surfaces.

Installation Procedure

    Object Number: 1239002 Size: SH
  1. If removed, install the throttle body. Refer to Throttle Body Assembly Replacement in Engine Controls - 3.5L.

    2. Object Number: 1239040 Size: SH
  2. Install the upper intake manifold gaskets.
  3. Install the upper intake manifold.

    4. Notice: Refer to Fastener Notice in the Preface section.

  4. Install the right upper intake manifold bolts and the stud.

    5. Tighten
    Tighten the bolts and the stud to 25 N·m (18 lb ft).

  5. Install the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement in Engine Controls - 3.5L.
  6. Install the MAP sensor bracket and the sensor. Refer to Manifold Absolute Pressure Sensor Replacement in Engine Controls - 3.5L.
  7. Install the EVAP canister purge valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement in Engine Controls - 3.5L.
  8. Install the ignition coil bracket with the coils. Refer to Ignition Control Module Replacement in Engine Controls - 3.5L.
  9. Install the following wiring harnesses to the retainers:
    10. • The engine wiring harness
    • The left side spark plug wire harness
    • The CMP sensor wiring harness
  10. Install the left side spark plug wires to the spark plugs. Refer to Spark Plug Wire Replacement in Engine Controls - 3.5L.
  11. Install the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls - 3.5L.
  12. Connect the electrical connectors to the following:
    13. • The EVAP canister purge valve
    •  The electronic throttle control
    • The IAT sensor
    • The MAF sensor
    • The EGR valve

    Object Number: 1239037 Size: SH
  13. Install the vacuum hoses to the following:
    14. • The heater and air conditioning source
    • The brake booster
    • The manifold vacuum source
    • The EVAP canister purge valve
  14. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  15. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.