Installation Procedure

WARNING: This page is about a different car, the 2003 Pontiac Grand Prix. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Refer to FASTENER NOTICE in Cautions and Notices.

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: Installing Thermostat, Gasket, And Water Outlet Housing
Courtesy of GENERAL MOTORS CORP.
Install the lower intake manifold gaskets.

Fig 2: Installing 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: Installing 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: Installing Lower Intake Manifold
Courtesy of GENERAL MOTORS CORP.
Install the lower intake manifold bolts (1-12).
Apply thread lock compound GM P/N 12345493 (Canadian P/N 10953488) 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: Tightening Lower Intake Manifold Bolts In 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: Installing Generator Brace Bracket Bolts
Courtesy of GENERAL MOTORS CORP.
Connect the ECT sensor electrical connector.

Fig 7: Connecting Electrical Connector
Courtesy of GENERAL MOTORS CORP.
Install the radiator inlet hose to the water outlet housing. Refer to RADIATOR HOSE REPLACEMENT - INLET (3.8L) in Engine Cooling.

Fig 8: Installing Radiator Inlet Hose To Water Outlet Housing
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: Installing EGR Outlet Pipe
Courtesy of GENERAL MOTORS CORP.
Install the drive belt tensioner. Refer to DRIVE BELT TENSIONER REPLACEMENT .
Install the generator brace. Refer to CHARGING SYSTEM or CHARGING SYSTEM in Generators and Regulators.
Install the upper intake manifold. Refer to INTAKE MANIFOLD REPLACEMENT - UPPER .

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

Fig 11: Installing Evaporative Emissions (EVAP) Canister Purge Solenoid
Courtesy of GENERAL MOTORS CORP.