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Installation Procedure

WARNING: This page is about a different car, the 2003 Pontiac Montana, 2003 Oldsmobile Silhouette, and 2003 Chevrolet Venture. However, it is still accessible from the selected car via links, so may be relevant.
  1. Apply 8-12 mm (0.08-0.11 in) bead of RTV Sealer GM P/N 12345739 or equivalent on each ridge where front and rear of the lower intake manifold contact the engine block (1).
  2. Install the lower intake manifold gaskets.
    NOTE: When replacing lower intake manifold gasket, a revised intake manifold gasket has been introduced by manufacturer. This new design gasket helps resolve issues related to intake manifold oil/coolant leaks. The gasket requires a revised torque specification and procedure in addition to the use of NEW revised intake manifold bolts. Please review TSB ENGINE OIL OR COOLANT LEAK (INSTALL NEW INTAKE MANIFOLD GASKET) for complete information.
  3. Install the push rods and tighten the valve rocker arms. Refer to VALVE ROCKER ARM AND PUSH ROD REPLACEMENT   . 
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  4. Install the valve rocker arm bolts.

    Tighten 

    Use the J 36660-A  to tighten the bolts to 19 N.m (14 lb ft) plus 30 degrees.

    Fig 1: Installing Lower Intake Manifold Gaskets And Seals
    G01485401Courtesy of GENERAL MOTORS CORP.
  5. Install the lower intake manifold.
    Fig 2: Installing Lower Intake Manifold
    G01485402Courtesy of GENERAL MOTORS CORP.
  6. Install the lower intake manifold bolts.
  7. Tighten the lower intake manifold bolts.
    Fig 3: Installing Lower Intake Manifold Bolts
    G01485403Courtesy of GENERAL MOTORS CORP.
    NOTE: Failure to tighten vertical bolts before the diagonal bolts may cause an oil leak.
  8. Apply sealer GM P/N 12345382 or the equivalent to the lower intake manifold bolt threads.
  9. Install the lower intake manifold bolts.

    Tighten  . See ENGINE OIL OR COOLANT LEAK (INSTALL NEW INTAKE MANIFOLD GASKET) for complete information.

    Tighten the bolts in sequence

    Fig 4: Tightening Lower Intake Manifold Bolts In Sequence
    G01485404Courtesy of GENERAL MOTORS CORP.
  10. Connect the thermostat bypass hose to the lower intake manifold pipe.
  11. Connect the inlet radiator hose from the engine. Refer to RADIATOR HOSE REPLACEMENT - INLET  in Engine Cooling.
    Fig 5: Connecting Thermostat Bypass Hose To Lower Intake Manifold Pipe
    G01485405Courtesy of GENERAL MOTORS CORP.
  12. Connect the heater inlet pipe and heater hose to the lower intake manifold. Refer to HEATING, VENTILATION AND AIR CONDITIONING  in Heating Ventilation and Air Conditioning.
  13. Install the power steering pump to the front engine cover. Refer to POWER STEERING PUMP REPLACEMENT  in Power Steering System.
    Fig 6: Connecting Heater Inlet Pipe And Heater Hose To Lower Intake Manifold
    G01485406Courtesy of GENERAL MOTORS CORP.
  14. Install the fuel injector rail. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION & OVERHAUL  in Removal and Installation in Engine Performance.
  15. Connect the fuel feed and return pipe to the fuel injector rail. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION & OVERHAUL  in Removal and Installation in Engine Performance.
    Fig 7: Installing Fuel Injector Rail
    G01485407Courtesy of GENERAL MOTORS CORP.

    Important:  The fuel injector wiring harness connectors must be connected to their respective fuel injectors. Failure to connect the fuel injector connectors to their respective fuel injectors may result in excessive exhaust emissions and poor engine performance.

  16. Install and connect the fuel injector, MAP and ECT wiring harness.
    Fig 8: Installing And Connect Fuel Injector, MAP And ECT Wiring Harness
    G01485408Courtesy of GENERAL MOTORS CORP.
  17. Install the wiring harness to the ECT sensor.
  18. Install the engine right side valve rocker arm cover. Refer to VALVE ROCKER ARM COVER REPLACEMENT - RIGHT   . 
  19. Install the engine left side valve rocker arm cover. Refer to VALVE ROCKER ARM COVER REPLACEMENT - LEFT   . 
  20. Install the upper intake manifold. Refer to INTAKE MANIFOLD REPLACEMENT - UPPER   . 
    Fig 9: Installing Wiring Harness To ECT Sensor
    G01485409Courtesy of GENERAL MOTORS CORP.
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