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Replacing Intake Manifold - Upper: Installation

WARNING: This page is about a different car, the 2006 Buick LaCrosse and 2006 Buick Allure. 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
    • PCV valve
    • MAP sensor
    • Throttle body
    2. Fig 1: Upper-To-Lower Intake Manifold Carrier Gasket & Upper Intake Manifold
    GM405818Courtesy of GENERAL MOTORS CORP.
  2. Install the upper-to-lower intake manifold carrier gasket to the upper intake manifold.
    3. Fig 2: Identifying Upper Intake Manifold Bolts & Studs
    GM910998Courtesy of GENERAL MOTORS CORP.
  3. Carefully install the upper intake manifold (5) 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. Apply thread lock compound GM P/N 12345382 (Canadian P/N 10953489), or equivalent, to the threads of the bolts (1, 4) and the studs (2, 3).
    5. Fig 3: Identifying Upper Intake Manifold Bolts Tightening Sequence
    GM49828Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in General Information.
  5. Install the upper intake manifold bolts and the studs (1-10).

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

    6. Fig 4: Fuel Rail Assembly & Fuel Injectors
    GM910936Courtesy of GENERAL MOTORS CORP.
  6. Lightly coat the fuel injectors (3) with clean engine oil.
    7. IMPORTANT: Ensure the fuel rail is fully seated in the lower intake manifold assembly.
  7. Install the fuel rail assembly (1) to the lower intake assembly.
  8. Install the fuel rail nuts (2).

    Tighten:  Tighten the nuts to 89 In. Lbs (10 N.m).

  9. Connect the EVAP purge solenoid pipe quick connect fitting. Refer to Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement in Engine Controls - 3.8L.
    10. Fig 5: EGR Valve Wiring Harness Heat Shield Nut & Bolt
    GM911071Courtesy of GENERAL MOTORS CORP.
  10. Install the EGR valve wiring harness heat shield (3), the nut (1) and the bolt (2).

    Tighten:  Tighten the nut and the bolt to 89 In. Lbs. (10 N.m).

    11. Fig 6: Brake Booster Hose & Vacuum Source Manifold
    GM910975Courtesy of GENERAL MOTORS CORP.
  11. Install the brake booster hose (1) to the vacuum source manifold (2).
  12. Connect the electrical connectors to the following:
    • MAF sensor
    • MAP sensor
    • EVAP purge solenoid
    • ETC
  13. Install the right spark plug wires to the ignition control module and the upper intake manifold. Refer to Spark Plug Wire Replacement in Engine Controls - 3.8L.
  14. Install the air cleaner intake duct. Refer to Air Cleaner Intake Duct Replacement in Engine Controls - 3.8L.
  15. Install the fuel injector sight shield. Refer to Replacing Fuel Injector Sight Shield .
  16. Fill the cooling system. Refer to Draining and Filling Cooling System (L26 Static Fill) or Draining and Filling Cooling System (L26, LY7, GE 47716 Fill) in Engine Cooling.
  17. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (L26) in Engine Electrical.
  18. Inspect for fluid or vacuum leaks.
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