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Home >> Chevrolet >> 2001 >> Camaro Base, 2D Convertible, Automatic >> Repair and Diagnosis >> External Pages >> Different car >> Section 63 (Engine Mechanical - 3.8L (On-Vehicle)) >> Repair Instructions >> Intake Manifold Replacement - Upper >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2002 Pontiac Firebird and 2002 Chevrolet Camaro. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install new lower intake manifold O-ring seal (3, 4), if removed.
    Fig 1: Installing New Lower Intake Manifold O-Ring Seal
    G01728731Courtesy of GENERAL MOTORS CORP.
  2. Install the upper intake manifold gasket (1).
    Fig 2: Installing Upper Intake Manifold Gasket
    G01728732Courtesy of GENERAL MOTORS CORP.
  3. Install the upper intake manifold (2) onto the lower intake manifold.
  4. Install the upper intake manifold bolts (1, 3, 4).

    Tighten 

    • Tighten the 9 upper intake manifold bolts (4) to 15 N.m (11 lb ft).
    • Tighten the 2 upper intake manifold bolts (1) to 30 N.m (22 lb ft).
    • Tighten the upper intake manifold bolt (3) to 15 N.m (11 lb ft).
    Fig 3: Installing Upper Intake Manifold Bolts
    G01728733Courtesy of GENERAL MOTORS CORP.
  5. If the upper intake manifold was replaced install the throttle body gasket (4) and the throttle body (3).
  6. Install the throttle body bolt (1) and nuts (2).

    Tighten 

    • Tighten the throttle body nuts (2) to 10 N.m (89 lb in).
    • Tighten the throttle body bolt (1) to 10 N.m (89 lb in).
    Fig 4: Installing Throttle Body Bolt
    G01728734Courtesy of GENERAL MOTORS CORP.
  7. Install the fuel rail (2) to the upper intake manifold.
    Fig 5: Installing Fuel Rail
    G01728735Courtesy of GENERAL MOTORS CORP.
  8. Install the fuel rail nuts (1).

    Tighten 

    Tighten the fuel rail nuts (1) to 9 N.m (80 lb in).

  9. Install the wiring harness clips to the fuel rail.
  10. Install the thermostat housing. Refer to THERMOSTAT HOUSING REPLACEMENT (3.8L ENGINE) .
  11. Reposition the engine wiring harness.
  12. Install the engine harness clamp (4) and harness clamp bolt (5).
    Fig 6: Installing Engine Harness Clamp And Harness Clamp Bolt
    G01728736Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the harness clamp bolt (5) to 6 N.m (53 lb in).

  13. Install the engine harness clip (3) to the throttle body.
  14. Connect the following electrical connectors:
    • MAF sensor (1)
    • ECT sensor (2)
  15. Connect the ETC electrical connector (1).
    Fig 7: Connecting ETC Electrical Connector
    G01728737Courtesy of GENERAL MOTORS CORP.
  16. Install the brake booster hose (2) to the upper intake manifold fitting (1).
    Fig 8: Installing Brake Booster Hose
    G01728738Courtesy of GENERAL MOTORS CORP.
  17. Position the brake booster hose clamp.
  18. Install the ignition control module. Refer to IGNITION CONTROL MODULE .
  19. If the upper intake manifold was replaced install the EVAP canister purge valve (2) to the upper intake manifold.
    Fig 9: Install EVAP Canister Purge Valve
    G01728739Courtesy of GENERAL MOTORS CORP.
  20. Install the EVAP canister purge valve bolts (1).

    Tighten 

    Tighten the EVAP canister purge valve bolts (1) to 10 N.m (89 lb in).

  21. Install the fuel vapor line (4) to the EVAP canister purge valve (5).
    Fig 10: Installing Fuel Vapor Line
    G01728740Courtesy of GENERAL MOTORS CORP.
  22. Install the fuel lines (1) to the fuel rail.
  23. Connect the EVAP canister purge valve electrical connector (2).
  24. Connect the left side fuel injector electrical connectors (1) to the fuel injectors.
    Fig 11: Connecting EVAP Canister Purge Valve Electrical Connector
    G01728741Courtesy of GENERAL MOTORS CORP.
  25. If the upper intake manifold was replaced install the manifold vacuum source (1) to the upper intake manifold.
    Fig 12: Installing Manifold Vacuum Source
    G01728742Courtesy of GENERAL MOTORS CORP.
  26. Install the manifold vacuum source screws (2).

    Tighten 

    Tighten the manifold vacuum source screws (2) to 10 N.m (89 lb in).

  27. Install the fuel pressure regulator tube (2) to the following components:
    • Manifold vacuum source (1)
    • Fuel pressure regulator valve (3)
    Fig 13: Install Fuel Pressure Regulator Tube
    G01728743Courtesy of GENERAL MOTORS CORP.
  28. Install the engine harness vacuum tube (1) to the vacuum port.
    Fig 14: Install Engine Harness Vacuum Tube
    G01728744Courtesy of GENERAL MOTORS CORP.
  29. Connect the MAP sensor electrical connector (2).
    Fig 15: Connecting MAP Sensor Electrical Connector
    G01728745Courtesy of GENERAL MOTORS CORP.
  30. Connect the right side fuel injector electrical connectors (1) to the fuel injectors.
  31. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
  32. Install the air intake duct.
    Fig 16: Installing Air Intake Duct
    G01728746Courtesy of GENERAL MOTORS CORP.
  33. Connect the IAT sensor electrical connector.
  34. Refill the engine coolant. Refer to DRAINING AND FILLING COOLING SYSTEM .
    Fig 17: Connecting IAT Sensor Electrical Connector
    G01728747Courtesy of GENERAL MOTORS CORP.
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