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Home >> Buick >> 2004 >> Century Limited >> Repair and Diagnosis >> External Pages >> Different car >> Section 87 (Engine Mechanical - 3.8L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Intake Manifold Replacement - Upper >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 Buick Regal. However, it is still accessible from the selected car via links, so may be relevant.
  1. If the manifold was replaced install the following:
    • Vacuum source manifold
    • Positive crankcase ventilation (PCV) valve
    • Manifold absolute pressure (MAP) sensor
    • Throttle body
    2. Fig 1: Upper-To-Lower Intake Manifold Carrier Gasket
    GM405818Courtesy of GENERAL MOTORS CORP.
  2. Install the upper-to-lower intake manifold carrier gasket to the upper intake manifold.
    3. Fig 2: Upper Intake Manifold, Bolts And Stud
    GM153570Courtesy of GENERAL MOTORS CORP.
  3. Carefully place the upper intake manifold onto the lower intake manifold. Ensure that the alignment pins in the upper intake manifold align with the holes in the lower intake manifold.
  4. Install the upper intake manifold.
  5. Apply thread lock compound GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the bolt threads before assembly.
    6. Fig 3: Installing Upper Intake Manifold Bolts
    GM49828Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  6. Install the upper intake manifold bolts (1-10).

    Tighten:  Tighten the bolts in sequence to 10 N.m (89 lb in).

  7. Install the accelerator and the cruise control cables with the bracket to the throttle body. Refer to Accelerator Controls Cable Bracket Replacement in Engine Controls - 3.8L.
  8. Install the EVAP purge solenoid vacuum line to the throttle body.
  9. Connect the electrical connectors to the following:
    • Mass air flow (MAF) sensor
    • Manifold absolute pressure (MAP) sensor
    • Idle air control (IAC) valve
    • Throttle position (T/P) sensor
    • EVAP purge solenoid
    10. Fig 4: Throttle Body Support Bracket
    GM153567Courtesy of GENERAL MOTORS CORP.
  10. Install the throttle body upper support bracket bolt.

    Tighten:  Tighten the bolt to 16 N.m (12 lb in).

    11. Fig 5: Installing EGR Valve Wiring Harness Heat Shield
    GM190554Courtesy of GENERAL MOTORS CORP.
  11. Install the EGR valve wiring harness heat shield, nut and bolt.

    Tighten:  Tighten the nut and the bolt to 10 N.m (89 lb in).

  12. Install the brake booster hose to the vacuum source manifold.
  13. Install the fuel rail assembly. Refer to Fuel Rail Assembly Replacement (L36) or Fuel Rail Assembly Replacement (L67) in Engine Controls - 3.8L.
  14. Install the right spark plug wires to the ignition control module. Refer to Spark Plug Wire Replacement in Engine Controls - 3.8L.
  15. Install the air cleaner intake duct. Refer to Air Cleaner Intake Duct Replacement in Engine Controls-3.8L.
  16. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (L36)  or Fuel Injector Sight Shield Replacement (L67) .
  17. Fill the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling.
  18. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  19. Inspect for fluid or vacuum leaks.
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