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.

NOTE: Refer to FASTENER NOTICE .

If removed, install the ECT sensor.
Tighten

Tighten the sensor to 25 N.m (18 lb ft).
If removed, install the thermostat, the gasket, and the water outlet housing.
Install the water outlet housing bolt and the stud.
Tighten

Tighten the bolt and the stud to 27 N.m (20 lb ft).

Fig 1: ECT Sensor
Courtesy of GENERAL MOTORS CORP.
Install the lower intake manifold gaskets.

Fig 2: Lower Intake Manifold Gaskets
Courtesy of GENERAL MOTORS CORP.
Apply sealer GM P/N 12346286 (Canadian P/N 10953472) or equivalent to the ends of the intake manifold seals.
Install the lower intake manifold seals.

Fig 3: Lower Intake Manifold Seals
Courtesy of GENERAL MOTORS CORP.

NOTE: The two bolts which fasten the lower intake manifold to the cylinder head are accessible only after the upper intake is removed. The bolts are located in the right front and left rear corners of the lower intake manifold. Remove the upper intake manifold to service the lower intake.
Install the lower intake manifold.

Fig 4: Lower Intake Manifold
Courtesy of GENERAL MOTORS CORP.
Install the lower intake manifold bolts (1-12). Apply thread lock compound GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the two hidden bolts and ensure they are installed.
Tighten

Tighten the lower intake manifold bolts in sequence to 15 N.m (11 lb ft).

Fig 5: Lower Intake Manifold Bolt Tightening Sequence
Courtesy of GENERAL MOTORS CORP.
Install the generator brace bracket.
Install the generator brace bracket bolts.
Tighten

Tighten the bolts to 50 N.m (37 lb ft).

Fig 6: Generator Brace Bracket
Courtesy of GENERAL MOTORS CORP.
Connect the ECT sensor electrical connector.

Fig 7: ECT Sensor Electrical Connector
Courtesy of GENERAL MOTORS CORP.
Install the radiator inlet hose to the water outlet housing. Refer to RADIATOR HOSE REPLACEMENT - INLET (3.1 L) or RADIATOR HOSE REPLACEMENT - INLET (3.8L) .

Fig 8: Radiator Inlet Hose
Courtesy of GENERAL MOTORS CORP.
Install the EGR outlet pipe to the lower intake manifold.
Install the EGR outlet pipe bolt to the lower intake manifold.
Tighten

Tighten the bolt to 29 N.m (21 lb ft).

Fig 9: EGR Outlet Pipe
Courtesy of GENERAL MOTORS CORP.
Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement (L36) or Drive Belt Tensioner Replacement (L67)
Install the generator brace.
Install the upper intake manifold. Refer to Intake Manifold Replacement - Upper .

Fig 10: Drive Belt Tensioner
Courtesy of GENERAL MOTORS CORP.
Install the evaporative emissions (EVAP) canister purge solenoid.
Inspect for fluid or vacuum leaks.

Fig 11: EVAP Canister Purge Solenoid
Courtesy of GENERAL MOTORS CORP.