Lower Intake Manifold Install
Installation ProcedureNotice: Applying excessive amounts of sealant may prohibit the intake gasket from sealing properly.
1. Apply a 4.0 mm (0.157 inch) patch of adhesive GM P/N 12346141 or equivalent to the cylinder head side of the lower intake manifold gasket at each end.
Important: The lower intake manifold gasket must be installed while the adhesive is still wet to the touch.
2. Install the lower intake manifold gasket onto the cylinder head.
Use the gasket locator pins in order to properly seat the lower intake manifold gasket on the cylinder head.
Notice: Care must be used to apply the correct amount of sealant onto the gaskets. Applying excessive amounts of sealant may prohibit the intake gaskets from sealing properly.
Important: The lower intake manifold must be installed and the fasteners tightened while the adhesive is still wet to the touch.
3. Apply a 5 mm (0.197 inch) bead of adhesive GM P/N 12346141 or equivalent to the front top of the engine block.
4. Extend the adhesive bead 13 mm (0.50 inch) onto each lower intake manifold gasket.
5. Apply a 5 mm (0.197 inch) bead of adhesive GM P/N 12346141 or equivalent to the rear top of the engine block.
6. Extend the adhesive bead 13 mm (0.50 inch) onto each lower intake manifold gasket.
7. Install the lower intake manifold onto the engine block.
Notice: Refer to Fastener Notice in Service Precautions.
8. If reusing the fasteners, apply threadlock GM P/N 12345382 or equivalent to the threads of the lower intake manifold bolts.
9. Install the lower intake manifold bolts.
Notice: Proper lower intake manifold fastener tightening sequence and torque is critical. Always follow the tightening sequence, and torque the intake manifold bolts using the 3 step method. Failing to do so may distort the crankshaft bearing bore alignment and cause damage to the crankshaft bearings.
10. Tighten the lower intake manifold bolts.
10.1. Tighten the bolts on the first pass in sequence (1-8) to 3 Nm (27 inch lbs.).
10.2. Tighten the bolts on the second pass in sequence (1-8) to 12 Nm (106 inch lbs.).
10.3. Tighten the bolts on the final pass in sequence (1-8) to 15 Nm (11 ft. lbs.).
11. Position the power steering pump mounting bracket.
12. Install the three bolts and the nut.
Notice: Refer to Fastener Notice in Service Precautions.
13. Install the front nut for the power steering pump rear bracket.
^ Tighten the power steering pump mounting bracket bolts, the nut, and the power steering pump rear bracket nuts to 41 Nm (30 ft. lbs.).
14. Install the drive belt.
15. Install the EGR valve inlet pipe to the intake manifold and the exhaust manifold.
15.1. Tighten the EGR valve inlet pipe intake manifold nut to 25 Nm (18 ft. lbs.).
15.2. Tighten the EGR valve inlet pipe exhaust manifold nut to 30 Nm (22 ft. lbs.).
15.3. Tighten the EGR valve inlet pipe clamp bolt 25 Nm (18 ft. lbs.).
16. Install the spark plug wire harness retainer on the EGR valve inlet pipe.
17. Install the PCV valve hose assembly to the intake manifold and the valve rocker arm cover.
18. Install the power brake booster vacuum hose to the intake manifold.
19. Install the EVAP canister purge solenoid valve hose.
20. Install the fuel supply and return pipes to the rear of the intake manifold.
Important: In order to install the distributor for the correct engine timing, position the engine to number one cylinder top dead center.
21. Remove the spark plug for number one cylinder.
22. Rotate the crankshaft until number one cylinder is in the compression stroke.
23. Align the two reference marks on the crankshaft balancer (1,4) with the two alignment marks (2,3) on the front cover.
24. Install the spark plug.
25. Install the distributor.
26. Install the water pump inlet hose to the intake manifold.
27. Install the heater hoses to the engine.
28. Install the radiator inlet hose to the thermostat housing.
29. Refill the cooling system.
30. Position the engine wiring harness and the engine wiring harness brackets.
31. Install the stud at the rear of the right cylinder head for the engine wiring harness bracket.
^ Tighten the engine wiring harness bracket stud to 25 Nm (18 ft. lbs.).
32. Install the nut holding the engine wiring harness bracket to the EVAP purge canister solenoid stud.
^ Tighten the engine wiring harness bracket nut to 9 Nm (80 inch lbs.).
33. Install the nut and the ground wire to engine wiring harness bracket stud at the rear of the right cylinder head.
^ Tighten the ground wire nut to 16 Nm (12 ft. lbs.).
34. Install the nuts and the engine wiring harness bracket to the upper intake manifold studs.
^ Tighten the engine wiring harness bracket nuts 12 Nm (106 inch lbs.).
35. Connect the following electrical connectors:
^ The EVAP canister purge solenoid valve (1)
^ The Manifold Absolute Pressure (MAP) sensor(2)
^ The Ignition Control Module (ICM) (4)
^ The ignition coil (3)
36. Connect the following electrical connectors: The A/C pressure switch (4), if equipped The A/C compressor clutch (1), if equipped The Exhaust Gas Recirculation (EGR) valve (2) The generator battery positive cable (3)
37. Connect the following electrical connectors:
^ The fuel meter body assembly (3)
^ The Throttle Position (TP) sensor (1)
^ The Idle Air Control (IAC) motor (2)
^ The Engine Coolant Temperature (ECT) sensor(4)
38. Connect the AIR crossover pipe to the AIR pipe assemblies.
39. Install the accelerator control cable bracket with the accelerator control cable and the cruise control cable and the nuts to the throttle body.
^ Tighten the nuts to 9 Nm (80 inch lbs.).
40. Install the engine wiring harness and clip to the accelerator control cable bracket.
41. Install the cruise control cable, if equipped to the throttle shaft and the accelerator control cable bracket.
42. Install the accelerator cable to the engine cable bracket.
43. Install the accelerator cable to the throttle body lever.
44. Install the accelerator cable to the cable routing bracket.
45. Connect the AIR crossover pipe to the AIR pipe assemblies.
46. Align the hinge clip with the lip on the throttle body.
Install the air inlet tube and resonator to the throttle body by pivoting the air inlet tube and resonator downward until the mounting stud is through the hole in the air inlet tube.
47. Install the resonator retaining wing nut.
48. Connect the PCV hose to the air cleaner outlet duct.
49. Connect the MAF/IAT sensor assembly harness connector.
50. Connect the battery negative cable.