Installation Procedure

WARNING: This page is about a different car, the 2002 Pontiac Grand Prix. However, it is still accessible from the selected car via links, so may be relevant.

Install the thermostat.

Fig 1: Thermostat
Courtesy of GENERAL MOTORS CORP.
Install the water outlet.
NOTE: Refer to FASTENER NOTICE .
Install the water outlet bolts.
Tighten

Tighten the bolts to 25 N.m (18 lb ft).

Fig 2: Water Outlet
Courtesy of GENERAL MOTORS CORP.
Install the ECT sensor.
Tighten

Tighten the sensor to 23 N.m (17 lb ft).

Fig 3: ECT Sensor
Courtesy of GENERAL MOTORS CORP.
Apply 8-12 mm (0.08-0.11 in) bead of RTV Sealer, GM P/N 12346286 (Canadian P/N 10953472) or equivalent, on each ridge where front and rear of the lower intake manifold contact the engine block (1).
Install the lower intake manifold gaskets.
NOTE: When replacing 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.
Install the valve rocker arms and pushrods. Refer to Valve Rocker Arm and Push Rod Replacement .

Fig 4: Lower Intake Manifold Gaskets
Courtesy of GENERAL MOTORS CORP.
Install the lower intake manifold.
Apply sealant, GM P/N 12345382 (Canadian P/N 10953489) to the threads of the bolts.

Fig 5: Lower Intake Manifold
Courtesy of GENERAL MOTORS CORP.
Install the lower intake manifold bolts (1, 2). See Fig 6,
NOTE: An oil leak may result if the vertical bolts are not tightened before the diagonal bolts.

Tighten See TSB For Revised Lower Intake Torque

Fig 6: Lower Intake Manifold Bolts
Courtesy of GENERAL MOTORS CORP.
Install the thermostat bypass hose to the thermostat bypass pipe and lower intake manifold pipe.
Install the radiator inlet hose to the engine. Refer to RADIATOR HOSE REPLACEMENT - INLET (3.1 L) or RADIATOR HOSE REPLACEMENT - INLET (3.8L) .

Fig 7: Thermostat Bypass Hose
Courtesy of GENERAL MOTORS CORP.
Install the heater inlet pipe and heater hose to the lower intake manifold.
Install the power steering pump to the front engine cover. Refer to POWER STEERING PUMP REPLACEMENT (3.8L) or POWER STEERING PUMP REPLACEMENT (3.1 L) .

Fig 8: Heater Inlet Pipe
Courtesy of GENERAL MOTORS CORP.
Install the fuel injector rail. Refer to FUEL RAIL & INJECTORS .

Fig 9: Fuel Injector Rail
Courtesy of GENERAL MOTORS CORP.
Install the fuel return pipe to the fuel injector rail. Refer to FUEL LINE DISCONNECT FITTINGS .

Fig 10: Fuel Return Pipe
Courtesy of GENERAL MOTORS CORP.
Install the fuel feed pipe to the fuel injector rail. Refer to FUEL LINE DISCONNECT FITTINGS .

Fig 11: Fuel Feed Pipe
Courtesy of GENERAL MOTORS CORP.
Install the fuel pipe clip.

Fig 12: Fuel Pipe Clip
Courtesy of GENERAL MOTORS CORP.
Install the fuel pipe clip bolt.
Tighten

Tighten the bolt to 8 N.m (71 lb in).

Fig 13: Fuel Pipe Clip Bolt
Courtesy of GENERAL MOTORS CORP.
Install and connect the fuel injector and the MAP sensor wiring harnesses.

Fig 14: Fuel Injector & MAP Sensor Wiring Harness
Courtesy of GENERAL MOTORS CORP.
Connect the ECT sensor electrical connector.
Install the right valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Right .
Install the left valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left .
Install the upper intake manifold. Refer to Intake Manifold Replacement - Upper .
Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE .
Inspect for leaks.

Fig 15: ECT Sensor Electrical Connector
Courtesy of GENERAL MOTORS CORP.