Intake Manifold Installation

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: View Of Intake Manifold Splash Shield

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Install the splash shield.
Ensure the splash shield (2) snap fits between the cylinder heads (1).

Fig 2: View Of Splash Shield Proper Installation Position

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Apply a 5 mm (0.2 in) bead of GM P/N 12346141 (Canadian P/N 10953433) sealer (1) to the 4 engine block/cylinder head locations.

Fig 3: View Of Engine Block/Cylinder Head Sealer Points

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Install the new intake manifold end seals.

Fig 4: View Of Intake Manifold End Seals

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Apply a 5 mm (0.2 in) bead of GM P/N 12346141 (Canadian P/N 10953433) sealer (1) onto the end seals at the 4 engine block/cylinder head locations.

Fig 5: View Of Engine Block/Cylinder Head End Seals Sealer Points

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Install the new intake manifold side gaskets onto the cylinder heads.

Fig 6: View Of Intake Manifold Side Gaskets

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Ensure the intake manifold gasket tabs align with the hole in the head gasket.
Ensure the intake manifold gasket tabs align with the slot in the intake manifold end seals.

Fig 7: View Of Manifold Gasket Tabs Aligning With Head Gasket Hold & Intake Manifold End Seals

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Install the intake manifold onto the engine block.

Fig 8: View Of Intake Manifold

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NOTE: Ensure the intake manifold does not shift as the intake manifold bolts are tightened in the proper sequence. Failure to follow the entire intake manifold bolt tightening sequence exactly, may result in an oil leak and serious engine damage.

IMPORTANT: The entire intake manifold tightening sequence must be promptly completed due to the anaerobic thread adhesive. The final pass of the tightening sequence must be completed before the adhesive starts to cure, or false torque readings and ineffective thread locking may result.

IMPORTANT: DO NOT reuse intake manifold bolts. Install NEW intake manifold bolts during assembly.

Install the NEW intake manifold bolts.

NOTE: Refer to Fastener Notice in Cautions and Notices.

Tighten the intake manifold bolts in sequence, using 4 passes.
Tighten:
1. Tighten the intake manifold bolts a first pass in sequence to 5 N.m (44 lb in).
2. Tighten the intake manifold bolts a second pass in sequence to 8 N.m (71 lb in). Inspect the intake manifold joints for signs of intake manifold shifting. Correct as required.
3. Tighten the intake manifold bolts a third pass in sequence to 12 N.m (106 lb in).
4. Tighten the intake manifold bolts a final pass in sequence to 15 N.m (11 lb ft).

Fig 9: View Of Intake Manifold Bolt Tightening Sequence

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IMPORTANT: Lubricate the injector O-ring seals with clean engine oil and install onto injector.

Install the fuel injection fuel rail with injectors.
Install the fuel injection fuel rail bolts/studs.
Tighten: Tighten the fuel injection fuel rail bolts/studs to 12 N.m (106 lb in).

Fig 10: View Of Fuel Injection Rail

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Install the throttle body gasket (501) and throttle body (502).
Install the throttle body nuts (503).
Tighten: Tighten the throttle body nuts to 10 N.m (89 lb in).

Fig 11: View Of Throttle Body, Nuts, Studs & Gasket

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Install the vacuum plug (513).

Fig 12: View Of Vacuum Plug

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