Intake Manifold Installation
Installation ProcedureImportant: Lubricate the injector O-ring seals with clean engine oil.
1. If replacing the intake manifold, install the fuel rail.
Notice: Refer to Fastener Notice in Service Precautions.
2. Install the fuel rail studs.
Tighten the fuel rail studs to 12 Nm (106 inch lbs.).
3. If replacing the intake manifold, install the fuel pressure regulator vacuum hose.
4. If replacing the intake manifold, install a NEW throttle body gasket.
5. Install the throttle body, and nuts.
Tighten the throttle body nuts to 10 Nm (89 inch lbs.).
6. If replacing the intake manifold, install a NEW EGR bracket gasket.
7. Install the EGR bracket, and nuts.
Tighten the EGR bracket nuts to 30 Nm (22 ft. lbs.).
Important: Lubricate the port of the MAP sensor with clean engine oil. Avoid dipping the sensor port directly into the lubricant or using a solid type of lubricant, as they may block the vacuum port signal.
8. If replacing the intake manifold, install the MAP sensor and bolt.
Tighten the MAP sensor bolt to 12 Nm (106 inch lbs.).
Important: Apply a very light film of clean engine oil to the purge solenoid seal.
9. If replacing the intake manifold, install the EVAP purge solenoid.
10. Apply sealant GM U.S. P/N 12345493, Canada P/N 10953488, or equivalent to the threads of the purge solenoid bolt.
11. Install the purge solenoid bolt.
Tighten the purge solenoid bolt to 10 Nm (89 inch lbs.).
12. Install the intake manifold oil splash shield.
13. Ensure the oil splash shield (2) snap fits between the cylinder heads (1).
14. Install NEW intake manifold end seals.
15. Install NEW intake manifold side gaskets.
16. Ensure the intake manifold gasket tabs align with the hole in the head gasket.
17. Ensure the intake manifold gasket tabs align with the slot in the intake manifold end seals.
18. Install the intake manifold.
Lower Intake Manifold Tightening Sequence:
19. Apply threadlock GM U.S. P/N 12345382, Canada P/N 10953489, or equivalent to a minimum of eight threads of the intake manifold bolts.
Important:
^ The entire intake manifold tightening sequence must be followed exactly, or an oil leak resulting in engine damage may occur. Ensure the intake manifold is tightened without allowing the intake manifold to shift.
^ The entire intake manifold tightening sequence must be promptly completed due to anaerobic thread adhesive. The final pass of the tightening sequence must be completed before the adhesive starts to cure, or false torque readings and ineffective thread locking may result.
20. Install the intake manifold bolts.
21. Tighten the intake manifold bolts in sequence, using four passes.
21.1. Snug the intake manifold bolts in sequence to 5 Nm (44 inch lbs.) on the first pass.
21.2. Snug 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.
21.3. Tighten the intake manifold bolts in sequence to 10 Nm (89 inch lbs.) on the third pass.
21.4. Tighten the intake manifold bolts in sequence to 12 Nm (106 inch lbs.) on the final pass.
22. Connect the fuel line quick connect fittings.
23. If equipped without RPO C5B, install the EVAP tube.
24. Connect the EVAP canister tube to the canister.
25. Connect the EVAP canister tube clip to the fuel rail.
26. If equipped without RPO C5B, connect the EVAP canister tube to the purge solenoid.
27. If equipped with RPO C5B, install the EVAP tube.
28. Connect the EVAP canister tube to the purge solenoid.
29. Connect the canister tube to the canister.
30. Position the wiring harness.
31. Install the wiring harness bolts.
Tighten the engine wiring harness bolts to 5 Nm (44 inch lbs.).
32. Connect the following electrical connectors:
^ TP sensor (2)
^ ETC (3)
^ EVAP purge solenoid (4)
33. Connect the following electrical connectors:
^ ECT sensor (1)
^ Ignition coil harness (2)
34. Install the A/C compressor and condenser hose.
35. Connect the following electrical connectors:
^ A/C compressor high pressure recirculate switch (1)
^ Fuel injector harness (2)
^ Ignition coil harness (3)
^ A/C compressor high pressure cutoff switch (4)
^ A/C compressor clutch switch (5)
36. Install the CPA retainers to the following electrical connectors:
^ Fuel injector harness (2)
^ Ignition coil harness (3)
37. Connect the MAP sensor electrical connector.
38. Install the EGR pipe bolts to the EGR bracket.
Tighten the EGR pipe bolts to 30 Nm (22 ft. lbs.).
39. Connect the EGR valve electrical connector (1).
40. Install the air intake duct and air cleaner element.
41. Tighten the air intake clamp at the throttle body.
Tighten the air intake duct clamp to 3 Nm (26 inch lbs.).
42. Install the air cleaner cover (1).
43. Engage the cover clips (2).
44. Connect the MAF sensor electrical connector (4).