Intake Manifold Installation

Special Tools 

EN-48896  HP Fuel Pump Installation Alignment Gauge

For equivalent regional tools, refer to Special Tools .

Fig 1: Intake Manifold Studs
Courtesy of GENERAL MOTORS COMPANY
CAUTION:

Refer to Fastener Caution .

1. Install the intake manifold studs in the manifold face and tighten to 15 N.m (11 lb ft).
Fig 2: Intake Manifold Retaining Nuts And Bolts
Courtesy of GENERAL MOTORS COMPANY
2. Install the intake manifold (1). Start and hand tighten the intake manifold bolts and nuts.
Fig 3: Intake Manifold Bolt Tightening Sequence
Courtesy of GENERAL MOTORS COMPANY
3. Tighten the bolts and nuts in sequence to 25 N.m (18 lb ft).
Fig 4: Fuel Rail Harness Connector Bracket And Intake Manifold Insulator
Courtesy of GENERAL MOTORS COMPANY
4. Install the intake manifold insulator (2).
5. Install the insulator bolt and tighten to 10 N.m (89 lb in).
6. Install the fuel rail harness connector bracket (1) to the intake manifold. Tighten the bracket bolt to 10 N.m (89 lb in).
Fig 5: Using Alignment Gage
Courtesy of GENERAL MOTORS COMPANY
NOTE:

The camshaft must be in the base circle position before the high pressure fuel pump is installed.

7. Use the EN-48896  alignment gauge (2) to ensure that the camshaft lobe is in the base circle position. At base circle position, the tool will be flush with the head (1).
Fig 6: Fuel Pump Assembly Components
Courtesy of GENERAL MOTORS COMPANY
8. Lubricate the high pressure fuel pump cylinder head bore with 5W-30 engine oil.
NOTE:

Ensure that the high pressure fuel pump roller lifter is oriented properly, the camshaft is at base circle, and the number 1 piston is at top dead center (TDC) on the exhaust stroke. The distance from the mounting flange surface to the camshaft at base circle should be 52 mm (2.05 in).

9. Lubricate the high pressure fuel pump roller lifter (1) with 5W-30 engine oil and install into the cylinder head bore.
10. Install a NEW fuel pump housing O-ring (2) and gasket (3).
NOTE:

Ensure the plastic bolt retainers are installed in the high pressure fuel pump mounting holes before installing.

11. Install the fuel pump assembly (4).
12. Start and hand-tighten the fuel pump assembly bolts evenly. Tighten the fuel pump bolts evenly to 15 N.m (11 lb ft).
Fig 7: High Pressure Fuel Line
Courtesy of GENERAL MOTORS COMPANY
13. Install and hand-tighten both ends of the NEW high pressure fuel line (1). Tighten the high pressure fuel line fitting nuts to 30 N.m (22 lb ft).
Fig 8: Fuel Pump Components
Courtesy of GENERAL MOTORS COMPANY
14. Install the fuel pump insulator (2).
NOTE:

The low pressure fuel pipe used is model dependent.

15. Install the low pressure fuel pipe assembly (1).
16. Install the fuel pump cover (3) and nut. Tighten the nut to 10 N.m (89 lb in).
17. Install the fuel pump cover bolts. Tighten the bolts to 10 N.m (89 lb in).
Fig 9: Throttle Body
Courtesy of GENERAL MOTORS COMPANY
18. Install a new throttle body gasket.
19. Install the throttle body (1).
20. Install the throttle body bolts and tighten to 10 N.m (89 lb in).
Fig 10: EVAP Canister Valve, Tube & MAP Sensor
Courtesy of GENERAL MOTORS COMPANY
21. Install the MAP sensor (3). Tighten the sensor bolt to 4 N.m (35 lb in).
22. Install the EVAP canister valve (2) and tighten to 25 N.m (18 lb ft).
23. Install the EVAP canister valve tube (1).
Fig 11: Oil Fill Cap Components
Courtesy of GENERAL MOTORS COMPANY
24. Install the O-ring and oil fill tube assembly (3).
25. Install the intake manifold cover (2) onto the camshaft cover ball studs.
26. Install the oil fill cap (1).