Intake Manifold Installation

Installation Procedure





1. If replacing the intake manifold, refer to Intake Manifold Assemble.
2. Install the splash shield.





3. Ensure the splash shield (2) snap fits between the cylinder heads (1).





4. Install NEW intake manifold end seals.





5. Install NEW intake manifold side gaskets onto the cylinder heads.





6. Ensure the intake manifold gasket tabs align with the hole in the head gasket.
7. Ensure the intake manifold gasket tabs align with the slot in the intake manifold end seals.





8. Install the intake manifold gaskets to the cylinder head with THIS SIDE UP stamped facing up.
9. Install the intake manifold to the engine block.
10. Apply bolt thread locking material GM P/N 12346004 or equivalent to the intake manifold bolts.





11. Install the intake manifold.
12. Apply thread adhesive GM P/N 12345382 or equivalent to a minimum of eight threads of the intake manifold bolts.
13. Install the intake manifold bolts.

Notice: Refer to Fastener Notice in Service Precautions.

14. Tighten the intake manifold bolts in sequence, using four passes as shown.
14.1. Tighten the intake manifold bolts in sequence to 5 Nm (44 inch lbs.) on the first pass.
14.2. Tighten the intake manifold bolts in sequence to 5 Nm (44 inch lbs.) on the second pass. Inspect the intake manifold joints for signs of intake manifold shifting. Correct as required.
14.3. Tighten the intake manifold bolts in sequence to 10 Nm (89 inch lbs.) on the third pass.
14.4. Tighten the intake manifold bolts in sequence to 12 Nm (106 inch lbs.) on the final pass.





Important: Lubricate the fuel injector O-ring seals with clean engine oil and install onto the spray tip of each injector.

15. If replacing the intake manifold, install the fuel rail.
16. Install the fuel rail studs.
^ Tighten the fuel rail studs to 12 Nm (106 inch lbs.).





17. Install the fuel pressure regulator vacuum hose.





18. Install the AIR pump pipe, if equipped.
19. Install the AIR pump pipe bolt to the cylinder head, if equipped.
^ Tighten the AIR pump pipe bolt to 50 Nm (37 ft. lbs.).





20. Install the AIR pump hose (1) to the pump pipe.
21. Reposition the AIR pump hose clamp.





22. Install a NEW AIR pipe gasket.
23. Connect the AIR pipe to the AIR pump pipe, if equipped.
24. Install the AIR pipe bolts at the exhaust manifold, if equipped.
25. Install the AIR pipe nut to the fuel rail stud, if equipped.
^ Tighten the AIR pipe bolts to 25 Nm (18 ft. lbs.).
^ Tighten the AIR pipe nut to 12 Nm (106 inch lbs.).





26. Install a NEW AIR pipe gasket.
27. Connect the AIR pipe to the AIR pump pipe, if equipped.
28. Install the AIR pipe bolts at the exhaust manifold, if equipped.
29. Install the (AIR) pipe nut to the fuel rail stud, if equipped.
^ Tighten the AIR pipe bolts to 25 Nm (18 ft. lbs.).
^ Tighten the AIR pipe nut to 12 Nm (106 inch lbs.).





30. Install a NEW EGR valve pipe gasket.
31. Position the EGR pipe.
32. Install the EGR pipe bolts at the EGR adapter.
^ Tighten the EGR pipe bolts to 30 Nm (22 ft. lbs.).





33. Connect the EGR valve electrical connector (1).





34. Install the bypass valve vacuum hose (1) to the intake manifold.





35. Position the engine harness over the engine compartment.
36. Connect the following electrical connectors:
^ Generator (1)
^ Injector harness (2)
^ Ignition coil harness (3)
^ TP sensor (4)
^ ETC (5)
^ Purge valve solenoid (6)
37. Install the CPA retainer at the ignition coil harness.
38. Install the engine harness bolt and studs
^ Tighten the engine harness bolt to 5 Nm (44 inch lbs.).
^ Tighten the engine harness stud to 10 Nm (89 inch lbs.).





39. Connect the following electrical connectors:
^ MAP sensor (1)
^ Ignition coil harness (2)
^ ECT sensor (3)
40. Install the CPA retainer at the ignition coil harness.





41. Position engine harness branch over the top of engine.
42. Connect the following electrical connectors:
^ Pressure cycling switch (1)
^ Surge tank switch (2)
^ MAF sensor (3)
43. Connect the engine harness clip to the wheelhouse splash shield.
44. Connect the engine harness clips to the studs on the front of dash.





45. Connect the fuel feed and return pipes.
46. Install the sight shield bracket (1) and nuts.
^ Tighten the sight shield bracket nuts to 5 Nm (44 inch lbs.).
47. Install the sight shield to the bracket (1).
48. Tighten the intake manifold sight shield bolt (3).
^ Tighten the intake manifold sight shield bolt to 10 Nm (89 inch lbs.).





49. Install the air cleaner outlet duct.
50. Tighten the clamps at the throttle body and air cleaner.
^ Tighten the air cleaner outlet duct clamp to 4 Nm (35 inch lbs.).