Intake Manifold Installation - Lower

WARNING: This page is about a different car, the 2004 Pontiac Aztek and 2004 Buick Rendezvous. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Lower Intake Manifold

Courtesy of GENERAL MOTORS CORP.

IMPORTANT: All gasket-mating surfaces need to be free of oil, and foreign material. Use GM P/N 12346139 (Canadian P/N 10953463) or equivalent to clean surfaces.

Install the lower intake manifold gaskets.
With gaskets in place apply a small drop 8-10 mm (0.31-0.39 in) of RTV sealer GM P/N 12346141 (Canadian P/N 10953433) or equivalent to the 4 corners of the intake manifold to block joint (1).
Connect the 2 small drops with a bead of RTV sealer that is between 8-10 mm (0.31-0.39 in) wide and 3.0-5.0 mm (0.12-0.20 in) thick (2).
Install the lower intake manifold.

Fig 2: Lower Intake Manifold Bolt Tightening Sequence

Courtesy of GENERAL MOTORS CORP.

NOTE: Maximum gasket performance is achieved when using new fasteners, which contain a thread-locking patch. If the fasteners are not replaced, a thread locking chemical must be applied to the fastener threads. Failure to replace the fasteners or apply a thread-locking chemical MAY reduce gasket sealing capability.

NOTE: Refer to Fastener Notice in Cautions and Notices.

IMPORTANT: All lower intake manifold bolts need to be cleaned, free of any foreign material, and reused only if new bolts are unavailable. Use GM P/N 12345382 (Canadian P/N 10953489) or equivalent and apply to the old intake manifold bolt threads.

IMPORTANT: Manufacturer recommends the center bolts be fully torqued before the diagonal bolts to assure proper seal ability.

IMPORTANT: Lower intake manifold bolts in location 6 and 7 should be torqued to specification using a crows foot type tool.

Install the lower intake manifold bolts.
Tighten:
1. Tighten the lower intake manifold bolts (1, 2, 3, 4) in sequence to 7 N.m (62 lb in) on the first pass.
2. Tighten the lower intake manifold bolts (5, 6, 7, 8) in sequence to 13 N.m (115 lb in) on the first pass.
3. Tighten the lower intake manifold bolts (1, 2, 3, 4) in sequence to 13 N.m (115 lb in) on the final pass.
4. Tighten the lower intake manifold bolts (5, 6, 7, 8) in sequence to 25 N.m (18 lb ft) on the final pass.

Fig 3: View Of Heater Inlet Pipe & Nut

Courtesy of GENERAL MOTORS CORP.

Install the heater inlet pipe.
Install the heater inlet pipe nut.
Tighten: Tighten the heater inlet pipe nut to 25 N.m (18 lb ft).

Fig 4: View Of Fuel Injector Rail Assembly

Courtesy of GENERAL MOTORS CORP.

IMPORTANT: Do not use the fuel injector O-ring seals twice. Install NEW fuel injector O-ring seals during assembly.

IMPORTANT: Do not press on the fuel pressure regulator valve when installing the fuel injector rail assembly.

Install the fuel injector rail assembly.
1. Install the fuel injector O-rings using GM P/N 12345616, (Canadian P/N 993182) or equivalent.
2. Install the injector nozzles into the lower intake manifold injector bores.
3. Press on the injector rail using the palms of both hands until the injectors are fully seated.
Install the fuel injector rail bolts.
Tighten: Tighten the fuel injector rail bolts to 10 N.m (89 lb in).

Fig 5: Fuel Feed & Return Pipe Retaining Clip

Courtesy of GENERAL MOTORS CORP.

IMPORTANT: Do not use the fuel injector O-ring seals twice. Install NEW fuel injector O-ring seals during assembly.

Install the fuel feed and return pipe retaining clip.
Install the fuel feed and return pipe retaining clip bolt.
Tighten: Tighten the fuel feed and return pipe retaining clip bolt to 8 N.m (71 lb in).