Intake Manifold Installation

Installation Procedure

Notice: Refer to Fastener Notice in Service Precautions.





1. If replacement of the intake manifold was required, install a NEW EGR valve gasket (3), the EGR valve (2), and EGR valve nuts (1).
^ Tighten the EGR valve nuts to 22 Nm (16 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.

2. If replacement of the intake manifold was required, 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.

3. If replacement of the intake manifold was required, install the purge solenoid and bolt.
^ Tighten the purge solenoid bolt to 10 Nm (89 inch lbs.).





4. If replacement of the intake manifold was required, install the fuel rail with injectors. Install the fuel rail studs and nuts.
^ Tighten the fuel rail studs and nuts to 12 Nm (106 inch lbs.).





5. If replacement of the intake manifold was required, install the fuel pressure regulator vacuum hose.





6. If replacement of the intake manifold is required, install a NEW throttle body gasket and the throttle body. Install the throttle body nuts.
^ Tighten the throttle body nuts to 10 Nm (89 inch lbs.).





7. Install the intake manifold splash shield.





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





9. Install NEW intake manifold end seals.





10. Install NEW intake manifold side gaskets.





11. Ensure the intake manifold gasket tabs align with the hole in the head gasket.
12. Ensure the intake manifold gasket tabs align with the slot in the intake manifold end seals.





13. Install the intake manifold.





14. 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.

15. Install the intake manifold bolts.
16. Tighten the intake manifold bolts in sequence, using four passes.
16.1. Snug the intake manifold bolts in sequence to 5 Nm (44 inch lbs.) on the first pass.
16.2. 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.
16.3. Tighten the intake manifold bolts in sequence to 10 Nm (89 inch lbs.) on the third pass.
16.4. Tighten the intake manifold bolts in sequence to 12 Nm (106 inch lbs.) on the final pass.
17. Connect the fuel line quick connect fittings.





18. Install the EVAP canister tube.
19. Connect the EVAP canister tube to the canister.
20. Connect the EVAP canister tube clip to the fuel rail.





21. Connect the EVAP emission canister tube to the purge solenoid.





22. Position the engine wiring harness to the intake manifold.
23. Install the passenger rear, and the drivers front and rear harness clip bolts to the top of the intake manifold.
^ Tighten the engine wiring harness clip bolts to 5 Nm (44 inch lbs.).
24. Install the harness to the passenger front clip. Close the clip.
25. Connect the following electrical connectors:
^ Ignition Coil (1)
^ TPS (3)
^ ETC (4)
26. Connect the vacuum hose to the rear of the intake manifold.





27. Connect the following electrical connectors:
^ MAP sensor (1)
^ EGR valve (2)





28. Install the ECT sensor wire clip to the ignition coil harness.
29. Connect the following electrical connectors:
^ Purge valve solenoid (1)
^ Ignition coil harness (2)
^ ECT sensor (3)





30. Position the EGR valve pipe.
31. Install the EGR valve pipe bolts (2) to the EGR valve.
^ Tighten the EGR valve pipe bolts to 25 Nm (19 ft. lbs.).





32. Position the A/C compressor.
33. Connect the following A/C compressor electrical connectors:
^ A/C compressor (1)
^ A/C high pressure switch (2)





34. Install the A/C compressor bolts.
^ Tighten the A/C compressor bolts to 50 Nm (37 ft. lbs.).





35. Install the Oil fill tube and bolt.
^ Tighten the Oil fill tube bracket bolt to 12 Nm (106 inch lbs.).
36. Install the engine cover.





37. Position the coolant recovery reservoir.
38. Install the coolant recovery reservoir bolt.
^ Tighten the coolant recovery reservoir bolt to 7 Nm (62 inch lbs.).





39. Install the air cleaner duct (3).
40. Position and tighten the clamp (2) at the throttle body (1).
^ Tighten the air cleaner duct clamp to 4 Nm (35 inch lbs.).





41. Install the air cleaner.
42. Install the air cleaner bolts.
^ Tighten the air cleaner bolts to 10 Nm (89 inch lbs.).
43. Tighten the clamp at the air cleaner.
^ Tighten the air cleaner duct clamp to 4 Nm (35 inch lbs.).





44. Connect the following electrical connectors:
^ MAP sensor (1)
^ IAT sensor (2)