LEMON Manuals: Even more car manuals for everyone
Home >> Cadillac >> 2004 >> CTS Base, 3.6 7 >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 7 (Engine Mechanical - 3.2L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Intake Plenum Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different variant/trim than selected.
  1. Assemble the intake plenum if necessary. Refer to Intake Plenum Manifold Assemble .
  2. Remove the masking from the intake plenum ports and ensure the sealing surfaces are clean and dry.
  3. Lightly coat the intake plenum O-ring seals with clean engine oil and install to the intake manifold.
  4. Position the intake plenum to the intake manifold, aligning the pins.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  5. Install the intake plenum bolts.

    Tighten:  Tighten the intake plenum bolts to 20 N.m (15 lb ft).

    Fig 1: Intake Plenum & Bolts
    GM764826Courtesy of GENERAL MOTORS CORP.
  6. Install the intake plenum bolt caps.
  7. Install the 2 bolts securing the ECM bracket to the intake plenum.

    Tighten:  Tighten the ECM bracket bolts to 8 N.m (71 lb in) in sequence 2-3.

    Fig 2: Expanded View Of ECM Bracket Bolts
    GM785761Courtesy of GENERAL MOTORS CORP.
  8. Connect the vacuum brake booster hose (3) to the vacuum source.
    Fig 3: Identifying Throttle Body Heater Inlet Hose/Pipe-To-Intake Plenum Bolt
    GM785825Courtesy of GENERAL MOTORS CORP.
  9. Install the bolt (1) securing the throttle body heater inlet hose/pipe to the intake plenum (2).

    Tighten:  Tighten the throttle body heater inlet hose/pipe bolt to 9 N.m(80 lb in).

  10. Connect the electrical connector (1) and vacuum hose (2) to the switchover valve at the rear of the plenum.
    Fig 4: Locating Electrical Connector & Vacuum Hose From Switchover Valve
    GM349112Courtesy of GENERAL MOTORS CORP.
  11. Position the remote power steering fluid reservoir (2) to the engine.
    Fig 5: Locating Remote Power Steering Fluid Reservoir Mounting Bolts
    GM785730Courtesy of GENERAL MOTORS CORP.
  12. Install the remote power steering fluid reservoir mounting bolts (1, 3).

    Tighten

    • Tighten the remote power steering fluid reservoir mounting bolts (1) to intake plenum to 9 N.m (80 lb in).
    • Tighten the remote power steering fluid reservoir mounting bolt (3) to cylinder head to 25 N.m (18 lb ft).
  13. Connect the vacuum brake booster hose retainer (1) to the rear of the intake plenum-RHD only.
  14. Connect the crankcase ventilation dirty air hose retainer (2) to the fuel pipe.
    Fig 6: Identifying Crankcase Ventilation Dirty Air Hose Retainer From Fuel Pipe
    GM794128Courtesy of GENERAL MOTORS CORP.
  15. Apply clean engine oil to the crankcase vent adapter seal.
  16. Position the crankcase vent adapter to the intake plenum.
  17. Install the 3 bolts securing the crankcase vent adapter to the intake plenum.

    Tighten:  Tighten the crankcase vent tube adapter bolts to 8 N.m (71 lb in).

    Fig 7: Identifying Crankcase Vent Adapter-To-Intake Plenum Bolts
    GM821099Courtesy of GENERAL MOTORS CORP.
  18. Inspect the following O-ring seals and replace if necessary:
    • The throttle body
    • The crankcase vent tubes
  19. Lightly lubricate the O-ring seals with clean engine oil.
  20. Position the throttle body to the intake plenum and crankcase vent adapter.
    Fig 8: Identifying Throttle Body-To-Intake Plenum Bolts
    GM345338Courtesy of GENERAL MOTORS CORP.
  21. Install the bolts securing the throttle body to the intake plenum.

    Tighten:  Tighten the throttle body bolts to 8 N.m (71 lb in).

  22. Connect the fuel pressure regulator atmospheric vent tube to the bottom of the throttle body.
    23. Fig 9: View Of Intake Plenum Air Inlet Hose Clamps & Hoses
    GM785802Courtesy of GENERAL MOTORS CORP.
  23. Install the intake plenum air inlet hose clamps and hoses to the throttle body.
scientia non olet · About LEMON Manuals