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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.
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 the surfaces.
    Fig 1: Identifying Intake Manifold Gaskets & Seals
    GM1557681Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: RTV sealer is NOT to be placed under the lower intake manifold gaskets.
  1. Install the lower intake manifold gaskets and seals.
    2. Fig 2: Identifying Valve Rocker Arm & Bolt
    GM1557679Courtesy of GENERAL MOTORS CORP.
  2. Coat the ends of the push rods using prelube GM P/N 12345501 (Canadian P/N 992704) or equivalent.
    3. IMPORTANT: The intake valve push rods measure 146.0 mm (5.75 in) and the exhaust valve push rods measure 152.5 mm (6.0 in).
  3. Install the push rods in their original location.
  4. Coat the rocker arm friction surfaces using prelube GM P/N 12345501 (Canadian P/N 992704) or equivalent.
    5. IMPORTANT: Shims (P/N 88894006) may be required under the valve rocker arm pedestals if reconditioning has been performed on the cylinder head or its components.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  5. Install the valve rocker arms in their original positions.
  6. Install the valve rocker arm bolts.

    Tighten:  Tighten the bolts to 34 N.m (25 lb ft).

    7. Fig 3: Installing Lower Intake Manifold
    GM1313742Courtesy of GENERAL MOTORS CORP.
  7. With the NEW gaskets and seals in place, apply a small drop, 8-10 mm (0.031-0.39 in) of RTV sealer GM P/N 12378521 (Canadian P/N 88901148) or equivalent to the 4 corners of the intake manifold to engine block joints (1).
  8. Install the lower intake manifold.
    9. Fig 4: Identifying Lower Intake Manifold Tightening Sequence
    GM1557861Courtesy 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.
  9. Apply sealer GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the lower intake manifold bolt threads.
  10. Install the lower intake manifold bolts.
  11. Tighten the lower intake manifold bolts in the sequence shown.

    Tighten: 

    1. Tighten the bolts (1, 2, 3, 4) in sequence to 16 N.m (12 lb ft).
    2. Tighten the bolts (5, 6, 7, 8) in sequence to 25 N.m (18 lb ft).

    12. Fig 5: Identifying Fuel Rail
    GM1557674Courtesy of GENERAL MOTORS CORP.
  12. Inspect the fuel rail (1), fuel injectors and fuel injector O-rings for damage and replace as necessary.
  13. Lubricate the fuel injector O-rings using GM P/N 12345616 (Canadian P/N 993182).
  14. Install the injector nozzles into the lower intake manifold injector bores.
  15. Press on the injector rail using the palms of both hands until the injector are fully seated.
  16. Install the fuel injector rail bolts.

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

  17. Connect the CMP sensor electrical connector.
  18. Position the fuel injector harness connector bracket to the intake manifold.
  19. Install the fuel injector harness connector bracket bolt.

    Tighten:  Tighten the bolt to 8 N.m (71 lb in).

    20. Fig 6: Identifying Fuel Injector Harness Connector & Bracket
    GM1675736Courtesy of GENERAL MOTORS CORP.
  20. Connect the engine harness electrical connector (3) to the fuel injector wiring harness electrical connector.
  21. Install the CPA retainer (2).
  22. Connect the fuel feed line to the fuel rail. Refer to METAL COLLAR QUICK CONNECT FITTING SERVICE .
  23. Connect the ECT electrical connector.
  24. Install the right valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Right .
  25. Install the left valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left .
  26. Install the upper intake manifold. Refer to Intake Manifold Replacement - Upper .
  27. Install the coolant crossover pipe. Refer to COOLANT CROSSOVER PIPE REPLACEMENT - LZ9 (3.9L) .
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