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Installation Procedure

WARNING: This page is about a different car, the 2006 Pontiac Montana SV6, 2006 Chevrolet Uplander, and 2006 Buick Terraza. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Lower Intake Manifold Gaskets & Seals
    GM61820Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: All gasket-mating surfaces need to be free of oil and foreign material. Use GM P/N 12346139 (Canadian P/N 10953463) or equivalent, to clean surfaces.
  1. Install the lower intake manifold gaskets.
  2. Install the valve rocker arms and pushrods. Refer to Valve Rocker Arm and Push Rod Replacement .
    3. Fig 2: View Of Lower Intake Manifold
    GM1313742Courtesy of GENERAL MOTORS CORP.
  3. With gaskets and seals in place apply a small drop 8-10 mm (0.31-0.39 in) of RTV sealer GM P/N 12378521 (Canadian P/N 88901148) or equivalent, to the 4 corners of the intake manifold to block joints (1).
  4. Install the lower intake manifold.
    5. Fig 3: Lower Intake Manifold Bolt Tightening Sequence
    GM187067Courtesy of GENERAL MOTORS CORP.
    NOTE: Maximum gasket performance is achieved when using new fasteners, which contain a thread-locking patch. If the fasteners are not replaced, a thread locking chemical must be applied to the fastener threads. Failure to replace the fasteners or apply a thread-locking chemical MAY reduce gasket sealing capability.
    NOTE: Failure to tighten vertical bolts before the diagonal bolts may cause an oil leak.
  5. Apply sealer GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the lower intake manifold bolt threads.
    6. NOTE: Refer to Fastener Notice in Cautions and Notices.
  6. Install the new lower intake manifold bolts, if applicable, in sequence.

    Tighten: 

    1. Tighten the lower intake manifold bolts in sequence to 13 N.m (115 lb in) on the first pass.
    2. Tighten the lower intake manifold bolts (1, 2, 3, 4) in sequence to 20 N.m (15 lb ft) on the final pass.
    3. Tighten the lower intake manifold bolts (5, 6, 7, 8) in sequence to 25 N.m (18 lb ft) on the final pass.

    7. Fig 4: View Of Heater Inlet Pipe & Nut
    GM523326Courtesy of GENERAL MOTORS CORP.
  7. Install the heater inlet pipe.
  8. Install the heater inlet pipe nut.

    Tighten:  Tighten the heater inlet pipe nut to 25 N.m (18 lb ft).

    9. Fig 5: Locating Thermostat
    GM187058Courtesy of GENERAL MOTORS CORP.
  9. Install the thermostat.
    10. Fig 6: Installing Water Outlet Bolts
    GM1239041Courtesy of GENERAL MOTORS CORP.
  10. Install the water outlet bolts. Refer to THERMOSTAT HOUSING REPLACEMENT - LX9 (3.5L) in Engine Cooling.
    11. Fig 7: Installing ECT Sensor
    GM1275978Courtesy of GENERAL MOTORS CORP.
  11. Install the ECT sensor.

    Tighten:  Tighten the ECT sensor to 20 N.m (15 lb ft).

    12. Fig 8: Connecting Thermostat Bypass Hose At Thermostat Bypass Pipe & Lower Intake Manifold Pipe
    GM190522Courtesy of GENERAL MOTORS CORP.
  12. Connect the thermostat bypass hose to the thermostat bypass pipe and lower intake manifold pipe.
  13. Connect the radiator inlet hose to the engine. Refer to Radiator Hose Replacement - Inlet in Engine Cooling.
  14. Connect the heater inlet pipe and heater hose to the lower intake manifold.
  15. Install the power steering pump to the front engine cover.
    16. Fig 9: View Of Fuel Rail With Injectors
    GM190516Courtesy of GENERAL MOTORS CORP.
  16. Install the fuel injector rail. Refer to Fuel Rail Assembly Replacement in Engine Controls - 3.5L.
    17. Fig 10: View Of Vacuum Hoses
    GM1239037Courtesy of GENERAL MOTORS CORP.
  17. Connect the fuel feed pipe to the fuel injector rail.
    18. Fig 11: Identifying MAP Sensor Wiring Harness
    GM190518Courtesy of GENERAL MOTORS CORP.
  18. Connect the fuel injector and MAP wiring harness.
  19. Connect the ECT wiring harness.
  20. Install the right valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Right .
  21. Install the left valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left .
  22. Install the upper intake manifold. Refer to Intake Manifold Replacement - Upper .
  23. Connect the battery ground negative cable. See Engine Electrical.
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