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Intake Manifold Assemble (L35)

WARNING: This page is about a different car, the 2002 GMC Savana and 2002 Chevrolet Chevy Express. However, it is still accessible from the selected car via links, so may be relevant.
  1. If reusing the fastener, apply threadlock GM P/N United States 12345382, GM P/N Canada 10953489, or equivalent, to the threads of the fuel meter body bracket bolt.
    NOTE: Refer to FASTENER NOTICE .
  2. Install the fuel meter body bracket and bolt.

    Tighten 

    Tighten the fuel meter bracket bolt to 10 N.m (89 lb in).

  3. Install the fuel meter body into the fuel meter body bracket.
  4. Install the 6 poppet nozzles into the proper lower intake manifold bores.
    Fig 1: Lower Intake Manifold & Poppet Nozzles
    G01689782Courtesy of GENERAL MOTORS CORP.
  5. Inspect the poppet nozzles in order to ensure that the poppet nozzles are firmly seated and locked in the lower intake manifold bores.
  6. Install a NEW fuel meter body seal into the groove of the fuel meter body.
  7. Install a NEW upper intake manifold to lower intake manifold gasket into the groove of the upper intake manifold.
  8. Install the upper intake manifold onto the lower intake manifold.
  9. If reusing the fasteners, apply threadlock GM P/N United States 12345382, GM P/N Canada 10953489, or equivalent, to the threads of the upper intake manifold attaching studs.
  10. Install the upper intake manifold attaching studs.

    Tighten 

    1. 10.1. Tighten the upper intake manifold attaching studs on the first pass to 5 N.m (44 lb in).
    2. 10.2. Tighten the upper intake manifold attaching studs on the final pass to 9 N.m (80 lb in).
    Fig 2: Installing Upper Intake Manifold & Studs
    G01689783Courtesy of GENERAL MOTORS CORP.
  11. If reusing the fasteners, apply threadlock GM P/N United States 12345382, GM P/N Canada 10953489, or equivalent, to the threads of the evaporative emission (EVAP) canister purge solenoid valve studs.
  12. Install the EVAP canister purge solenoid valve and studs.

    Tighten 

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

  13. Install the engine wiring harness bracket and nut.

    Tighten 

    Tighten the engine wiring harness bracket nut to 12 N.m (106 lb in).

    Fig 3: Engine Wiring Harness Bracket, Studs & Nut
    G01689784Courtesy of GENERAL MOTORS CORP.
  14. Install the NEW fuel seals (8), black O-rings, into the fuel meter body.
  15. Install the NEW spacer rings (7), flat washers, into the fuel meter body.
  16. Install the NEW fuel seals (6), yellow O-rings, into the fuel meter body.
  17. Install the NEW fuel seal retainers (5) into the fuel meter body.
  18. Install the fuel pipe (3) into the fuel meter body.
  19. Install the fuel pipe retainer bracket (2) onto the fuel pipe.
  20. Install the fuel pipe retainer bracket nuts (1).
  21. If reusing the fastener, apply threadlock GM P/N United States 12345382, GM P/N Canada 10953489, or equivalent, to the threads of the fuel pipe bolt.
  22. Install the fuel pipe bolt (4).
    Fig 4: Fuel Pipe Components
    G01689785Courtesy of GENERAL MOTORS CORP.

    Tighten 

    1. 22.1. Tighten the fuel pipe bracket nuts to 3 N.m (27 lb in).
    2. 22.2. Tighten the fuel pipe bolt to 6 N.m (53 lb in).
  23. Install a NEW manifold absolute pressure (MAP) sensor seal onto the MAP sensor.
  24. Apply a small amount, approximately 1 drop, of clean engine oil to the MAP sensor seal.
  25. Install the MAP sensor into the upper intake manifold.
    Fig 5: Installing MAP Sensor & Seal
    G01689786Courtesy of GENERAL MOTORS CORP.
  26. Install the ignition coil and studs.

    Tighten 

    Tighten the ignition coil studs to 12 N.m (106 lb in).

    Fig 6: Installing Ignition Coil & Studs
    G01689787Courtesy of GENERAL MOTORS CORP.
  27. If reusing the engine coolant temperature (ECT) sensor plug (1) or the ECT sensor (2), if equipped, apply sealant GM P/N United States 12346004, GM P/N Canada 10953480, or equivalent, to the threads of the ECT sensor plug (1) or the ECT sensor (2).
  28. Install the ECT sensor or plug, if equipped, into the front of the lower intake manifold.

    Tighten 

    Tighten the ECT sensor or plug to 20 N.m (15 lb ft).

    Fig 7: Installing ECT Sensor
    G01689788Courtesy of GENERAL MOTORS CORP.

    Important:  The exhaust gas recirculation (EGR) valve must be installed in the original orientation. Some applications will not have an EGR valve.

  29. Install a NEW EGR valve gasket and the EGR valve.
    Fig 8: Installing EGR Valve & Gasket
    G01689789Courtesy of GENERAL MOTORS CORP.
  30. Install the EGR valve bolts.

    Tighten 

    1. 30.1. Tighten the EGR valve bolts on the first pass to 7 N.m (62 lb in).
    2. 30.2. Tighten the EGR valve bolts on the final pass to 30 N.m (22 lb ft).
    Fig 9: Installing EGR Valve Bolts
    G01689790Courtesy of GENERAL MOTORS CORP.
  31. Install the engine coolant thermostat.
  32. Install the water outlet (1 or 2).
  33. Install the water outlet studs.

    Tighten 

    Tighten the water outlet studs to 25 N.m (18 lb ft).

    Fig 10: Installing Water Outlet & Studs
    G01689791Courtesy of GENERAL MOTORS CORP.
  34. Install a NEW throttle body gasket into the groove in the upper intake manifold.
  35. Install the throttle body onto the upper intake manifold.
    Fig 11: Installing Throttle Body & Gasket
    G01689792Courtesy of GENERAL MOTORS CORP.
  36. If reusing the fasteners, apply threadlock GM P/N United States 12345382, GM P/N Canada 10953489, or equivalent, to the threads of the throttle body attaching studs.
  37. Install the throttle body attaching studs.

    Tighten 

    Tighten the throttle body attaching studs to 9 N.m (80 lb in).

    Fig 12: Throttle Body Attaching Studs
    G01689793Courtesy of GENERAL MOTORS CORP.
  38. Install the accelerator control cable bracket, the studs, and the nuts.

    Tighten 

    1. 38.1. Tighten the accelerator control cable bracket stud to the intake manifold to 6 N.m (53 lb in).
    2. 38.2. Tighten the accelerator control cable bracket nuts to 12 N.m (106 lb in).
    3. 38.3. Tighten the accelerator control cable bracket stud to the throttle body to 12 N.m (106 lb in).
    Fig 13: Accelerator Control Cable Bracket, Studs & Nuts
    G01689794Courtesy of GENERAL MOTORS CORP.
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