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Home >> Chevrolet >> 2001 >> Venture Base, Van Passenger >> Repair and Diagnosis >> External Pages >> Different car >> Section 888 (Engine Mechanical - 3.8L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Intake Manifold Replacement - Upper >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2003 Buick Regal. However, it is still accessible from the selected car via links, so may be relevant.
  1. If the manifold was replaced install the following:
    • Vacuum source manifold
    • Positive crankcase ventilation (PCV) valve
    • Manifold absolute pressure (MAP) sensor
    • Throttle body
  2. Install the upper-to-lower intake manifold carrier gasket to the upper intake manifold.
    Fig 1: Installing Upper-To-Lower Intake Manifold Carrier & Gasket
    G01968418Courtesy of GENERAL MOTORS CORP.
  3. Carefully place the upper intake manifold onto the lower intake manifold. Ensure that the alignment pins in the upper intake manifold align with the holes in the lower intake manifold.
  4. Install the upper intake manifold.
    Fig 2: Installing Upper Intake Manifold
    G01968419Courtesy of GENERAL MOTORS CORP.
  5. Apply thread lock compound GM P/N 12345382, (Canadian P/N 10953489) or equivalent, to the bolt threads before assembly.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  6. Install the upper intake manifold bolts (1-10).

    Tighten 

    Tighten the bolts in sequence to 10 N.m (89 lb in).

    Fig 3: Tightening Sequence Of Upper Intake Manifold Bolts
    G01968420Courtesy of GENERAL MOTORS CORP.
  7. Install the accelerator and the cruise control cables with the bracket to the throttle body.
  8. Install the EVAP purge solenoid vacuum line to the throttle body.
  9. Connect the electrical connectors to the following:
    • Mass air flow (MAF) sensor
    • Manifold absolute pressure (MAP) sensor
    • Idle air control (IAC) valve
    • Throttle position (T/P) sensor
    • EVAP purge solenoid
  10. Install the throttle body upper support bracket bolt.

    Tighten 

    Tighten the bolt to 16 N.m (12 lb in).

    Fig 4: Installing Throttle Body Upper Support Bracket Bolt
    G01968421Courtesy of GENERAL MOTORS CORP.
  11. Install the EGR valve wiring harness heat shield, nut and bolt.

    Tighten 

    Tighten the nut and the bolt to 10 N.m (89 lb in).

  12. Install the brake booster hose to the vacuum source manifold.
  13. Install the fuel rail assembly. Refer to FUEL RAIL & INJECTORS in Removal & Installation.
  14. Install the right spark plug wires to the ignition control module.
  15. Install the air cleaner intake duct. Refer to AIR CLEANER INTAKE DUCT in Removal & Installation - A/T.
  16. Install the fuel injector sight shield. Refer to FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L36)  or FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L67)  .
    Fig 5: Installing EGR Valve Wiring Harness Heat Shield
    G01968422Courtesy of GENERAL MOTORS CORP.
  17. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
  18. Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Battery.
  19. Inspect for fluid or vacuum leaks.
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