Installation

1. Apply a 5 mm (0.189 inches) bead of RTV sealer, GM P/N 12346192 or the equivalent, to the front of the engine block. Extend the bead 13 mm (0.5 inches) up each cylinder head in order to the seal and retain the gaskets.





2. Apply a 5 mm (0.189 inches) bead of RTV sealer, GM P/N 12346192 or the equivalent, to the rear of the engine block. Extend the bead 13 mm (0.5 inches) up each cylinder head in order to the seal and retain the gaskets.





3. Install the intake manifold with the new gaskets.





4. Install the intake manifold bolts and the studs.
^ Tighten the intake manifold bolts and the studs in a first pass to 10 Nm (89 inch lbs.) in sequence.
^ Tighten the intake manifold bolts and studs in the second pass to the final specifications of 50 Nm (37 ft. lbs.) in sequence.





5. Install the throttle body, gasket, and bolts. Tighten the throttle body bolts to 25 Nm (18 ft. lbs.).
6. Connect the connectors to the Throttle Position (TP) sensor and the Idle Air Control (IAC) sensor.





7. Install the coolant hoses to the throttle body.





8. Install the generator rear brace. See Starting and Charging.





9. Install the secondary air injection pipe to the exhaust manifold. Tighten the secondary air injection pipe to 55 Nm (41 ft. lbs.).





10. Install the EGR valve pipe, stud and the nut.
11. Install the EGR valve and the nuts.
^ Tighten the EGR valve pipe stud to 12 Nm (106 inch lbs.).
^ Tighten the EGR valve pipe nut to 25 Nm (18 ft. lbs.).
^ Tighten the EGR valve nuts to 30 Nm (22 ft. lbs.).
^Tighten the EGR pipe to exhaust manifold bolt to 30 Nm (22 ft. lbs.).





12. Install the EGR control valve relay and the nut. Tighten the EGR control valve relay nut to 25 Nm (18 ft. lbs.).





13. Install the emission canister purge solenoid and the bracket bolt. Tighten the emission canister purge solenoid bracket bolt to 6 Nm (53 inch lbs.).





14. Connect the EGR valve vacuum harness.





15. Install the fuel pressure regulator vacuum tube.





16. Install the fuel rail to the intake manifold.
17. Install the fuel rail bolts.
18. Tighten the fuel rail bolts to 10 Nm (89 inch lbs.).
19. Connect clip attaching the wiring harness to the fuel rail.





20. Install the fuel pipe connectors to the fuel rail.
21. Install the secondary air injection diverter valve hoses.
22. Install the accelerator cable bracket, bolts, cables and cover. Tighten the accelerator cable bracket bolts to 12 Nm (106 inch lbs.).
23. Install the accelerator control/cruise control servo cable adjuster, if equipped.





24. Install the wiring harness connectors to the fuel injectors.
25. Connect clips attaching the fuel lines the throttle linkage cover.
26. Connect the Intake Air Temperature (IAT) sensor and Mass Airflow (MAF) sensor connectors.
27. Install the negative battery cable.
28. Refill with coolant. See Cooling System.