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Home >> Chevrolet >> 2001 >> Venture Base, Van Passenger >> Repair and Diagnosis >> External Pages >> Different car >> Section 789 (Engine Mechanical (On-Vehicle)) >> Repair Instructions >> Intake Manifold Replacement - Lower >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2002 Pontiac Montana, 2002 Oldsmobile Silhouette, and 2002 Chevrolet Venture. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Lower Intake Manifold Gaskets & Seals
    G01828721Courtesy of GENERAL MOTORS CORP.
  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.
  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 .
  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.

  5. Install the lower intake manifold.
    Fig 2: Lower Intake Manifold
    G01828722Courtesy of GENERAL MOTORS CORP.
  6. Install the lower intake manifold bolts.
  7. Tighten the lower intake manifold bolts.
    Fig 3: Lower Intake Manifold Bolts
    G01828723Courtesy 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 

    Tighten the bolts in sequence to 13 N.m (115 lb in).

    Fig 4: Lower Intake Manifold Bolts Tightening Sequence
    G01828724Courtesy of GENERAL MOTORS CORP.
  10. Connect the thermostat bypass hose to the lower intake manifold pipe.
    Fig 5: Thermostat Bypass Hose
    G01828725Courtesy of GENERAL MOTORS CORP.
  11. Connect the inlet radiator hose from the engine. Refer to RADIATOR HOSE REPLACEMENT - INLET .
    12. Fig 6: Heater Inlet Pipe
    G01828726Courtesy of GENERAL MOTORS CORP.
  12. Connect the heater inlet pipe and heater hose to the lower intake manifold. Refer to HEATER PIPE REPLACEMENT - INLET .
  13. Install the power steering pump to the front engine cover. Refer to POWER STEERING PUMP REPLACEMENT .
    14. Fig 7: Fuel Injector Rail
    G01828727Courtesy of GENERAL MOTORS CORP.
  14. Install the fuel injector rail. Refer to FUEL RAIL & INJECTORS .
  15. Connect the fuel feed and return pipe to the fuel injector rail. Refer to FUEL HOSES/PIPES - ENGINE COMPARTMENT .

    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: Fuel Injector, Manifold Air Pressure & ECT Wiring Harness
    G01828728Courtesy of GENERAL MOTORS CORP.
  17. Install the wiring harness to the ECT sensor.
    Fig 9: Wiring Harness For Engine Coolant Temperature Sensor
    G01828714Courtesy of GENERAL MOTORS CORP.
  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 .
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