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Home >> Buick >> 2007 >> Lucerne CX >> Repair and Diagnosis >> External Pages >> Different car >> Section 237 (Engine Mechanical - 3.9L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Intake Manifold Replacement - Upper >> Installation Procedure

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: Identifying Inlet Manifold Tuning Valve
    GM1557831Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice .
  1. Install the inlet manifold tuning valve and bolts.

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

    2. Fig 2: Identifying EVAP Canister Purge Solenoid Valve
    GM1639213Courtesy of GENERAL MOTORS CORP.
  2. Inspect the EVAP canister purge solenoid valve seal for damage, replace as necessary.
  3. Install the EVAP canister purge solenoid valve (3) and bolt (2).

    Tighten:  Tighten the bolts to 16 N.m (12 lb ft).

  4. Inspect the MAP sensor seal for damage, replace as necessary.
  5. Install the MAP sensor (1), bracket and bolts.
  6. Inspect the throttle body seal for damage, replace as necessary.
  7. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the throttle body bolts/studs threads.
  8. Install the throttle body and bolts/studs.

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

    9. Fig 3: Identifying Upper Intake Manifold Gaskets
    GM1582017Courtesy of GENERAL MOTORS CORP.
  9. Install the NEW upper to lower intake manifold gaskets.
    10. Fig 4: Identifying Upper Intake Manifold
    GM1582016Courtesy of GENERAL MOTORS CORP.
  10. Set the upper intake manifold onto the lower intake manifold.
  11. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the upper intake manifold bolts/stud threads.
  12. Install the upper intake manifold bolts (1, 2) and stud (3).

    Tighten:  Tighten the bolts and stud to 25 N.m (18 lb ft).

  13. Install the ignition coil. Refer to IGNITION COIL REPLACEMENT .
  14. Reposition the transmission tube and install the bolt at the intake manifold.
  15. Install the bracket from the generator to the intake manifold.
  16. Install the bolt connecting the generator, bracket and the intake manifold.
  17. Install the nut connecting the generator bracket to the upper intake manifold.
    18. Fig 5: Identifying Air Cleaner Outlet Duct Nuts
    GM1675739Courtesy of GENERAL MOTORS CORP.
  18. Install the inlet and outlet pipe to the studs.
  19. Install the heater inlet and outlet pipe nuts (1) to the throttle body studs.

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

    20. Fig 6: View Of Left Spark Plug/Coil Harness
    GM1582091Courtesy of GENERAL MOTORS CORP.
  20. Install the left side spark plug wires.
  21. Connect the left side spark plug wires to the spark plugs.
  22. Connect the left side spark plug wires to the ignition control module.
  23. Engage the spark plug wire retainer clips to the intake manifold bracket and the heater inlet/outlet pipe.
  24. Install the air cleaner outlet duct. Refer to AIR CLEANER OUTLET DUCT REPLACEMENT .
    25. Fig 7: Identifying Engine Harness electrical Connector
    GM1675736Courtesy of GENERAL MOTORS CORP.
  25. Connect the engine harness electrical connector (1) to the intake manifold tuning valve.
    26. Fig 8: Locating EVAP & ETC Electrical Connectors
    GM1675738Courtesy of GENERAL MOTORS CORP.
  26. Connect the engine harness electrical connectors (1, 2) to the following:
    • EVAP canister purge solenoid
    • ETC
    27. Fig 9: Locating MAP Sensor Electrical Connector
    GM1675732Courtesy of GENERAL MOTORS CORP.
  27. Connect the MAP sensor electrical connector (1).
  28. Install the brake booster vacuum hose to the intake manifold.
  29. Position the vacuum hose clamp at the intake manifold.
    30. Fig 10: Identifying Positive Crankcase Ventilation (PCV) Foul Air Tube
    GM1582012Courtesy of GENERAL MOTORS CORP.
  30. Install the PCV foul air tube. Refer to PLASTIC COLLAR QUICK CONNECT FITTING SERVICE .
    31. Fig 11: Identifying Positive Crankcase Ventilation (PCV) Fresh Air Tube
    GM1582009Courtesy of GENERAL MOTORS CORP.
  31. Install the PCV fresh air tube. Refer to PLASTIC COLLAR QUICK CONNECT FITTING SERVICE .
  32. Fill the cooling system. Refer to Draining and Filling Cooling System (Static Fill) or Draining and Filling Cooling System (Vac-N-Fill) .
  33. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .
  34. Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE .
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