Upper Intake Manifold Installation

Installation Procedure





1. Install the throttle body, if removed.
2. Install the MAP sensor, if removed.
3. Install the PCV valve cover, if removed, using the following procedure:
3.1. Install a NEW seal (O-ring) on the PCV valve cover.
3.2. Lubricate the seal with clean engine oil.
3.3. Install the PCV valve cover in the upper intake manifold.
3.4. Turn and lock the PCV valve cover in position.





4. Install the power brake-booster vacuum tube fitting, if removed, using-the following procedure:
4.1. Install a NEW seal (O-ring) on the power brake booster vacuum tube fitting.
4.2. Lubricate the seal with clean engine oil.
4.3. Install the power brake booster vacuum tube fitting in the upper intake manifold.
4.4. Turn and lock the power brake booster vacuum tube fitting in position.





5. Install a NEW seal on the fuel meter body assembly.
6. Lubricate the seal with clean engine off.





7. Install a NEW upper intake manifold to lower intake manifold gasket in the groove of the upper intake manifold.





8. Install the; upper intake manifold-onto the lower intake manifold.
9. If reusing the fasteners, apply threadlock GM P/N 12345382 or equivalent to the threads of the upper intake manifold attaching bolts.

Notice: Refer to Fastener Notice in Service Precautions.

10. Install the upper intake manifold attaching studs.
10.1. Tighten the upper intake manifold attaching studs on the first pass to 5 Nm (44 inch lbs.).
10.2. Tighten the upper intake manifold attaching studs on the final pass to 9 Nm (80 inch lbs.).
11. Install the fuel lines to the fuel meter body assembly.
12. Install the EVAP canister purge solenoid valve.





13. Install the accelerator control cable bracket to the throttle body and the intake manifold.
^ Tighten the accelerator control cable bracket studs and nuts to 12 Nm (106 inch lbs.).





14. Connect the PCV valve hose assembly to the intake manifold and the valve rocker arm cover.





15. Connect the power brake booster vacuum hose to the intake manifold.





16. Position the engine wiring harness and engine wiring harness brackets.
17. Install the stud holding the engine wiring harness bracket to the rear of the right cylinder head.
^ Tighten the engine wiring harness bracket stud to 25 Nm (18 ft. lbs.).
18. Install the nut holding the engine wiring harness bracket to the stud at the EVAP canister purge solenoid valve.
^ Tighten the engine wiring harness bracket nut to 9 Nm (80 inch lbs.).
19. Install the nut and the ground wire on the engine wiring harness bracket stud at the rear of the right cylinder head.
^ Tighten the ground wire nut to 16 Nm (12 ft. lbs.).





20. Install the engine wiring harness bracket on the upper intake manifold studs.
21. Install the engine wiring harness bracket nuts.
^ Tighten the engine wiring harness bracket nuts to 12 Nm (106 inch lbs.).





22. Connect the following electrical connections:
^ The A/C compressor clutch (1), if equipped
^ The A/C pressure switch (4), if equipped
^ The EGR valve (2)





23. Connect the following electrical connections:
^ The Throttle Position (TP) sensor (1)
^ The Idle Air Control (IAC) motor (2)
^ The fuel meter body assembly connector (3)





24. Connect the following electrical connections:
^ The Manifold Absolute Pressure (MAP) sensor(2)
^ The EVAP canister purge solenoid valve (1)





25. 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 accelerator control cable bracket nuts to 9 Nm (80 inch lbs.).





26. Install the engine wiring harness clip to the accelerator control cable bracket.





27. Install the cruise control cable, if equipped to the throttle shaft and the accelerator control cable bracket.
28. Install the accelerator cable to the engine cable bracket.
29. Install the accelerator cable to the throttle body lever.





30. Install the accelerator cable to the cable routing bracket.





31. Connect the AIR crossover pipe to the AIR pipe assemblies.





32. 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.





33. Install the resonator retaining wing nut.
34. Connect the PCV hose to the air cleaner outlet duct.





35. Connect the MAF/IAT sensor assembly harness connector.