Installation Procedure

WARNING: This page is about a different car, the 2003 GMC Envoy XL and 2003 Chevrolet TrailBlazer. However, it is still accessible from the selected car via links, so may be relevant.

Install NEW intake manifold gaskets (1) to the intake manifold.

Fig 1: Installing Intake Manifold Gaskets To Intake Manifold
Courtesy of GENERAL MOTORS CORP.
Install the intake manifold.
Apply a 5 mm (0.20 in) bead of threadlock GM P/N 12345382, (Canadian P/N 10953489) or equivalent to the threads of the intake manifold bolts.

Fig 2: Installing Intake Manifold
Courtesy of GENERAL MOTORS CORP.

NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
Install the intake manifold bolts.
Tighten
1. 4.1. Tighten the bolts a first pass in sequence to 5 N.m (44 lb in).
2. 4.2. Tighten the bolts a final pass in sequence to 10 N.m (89 lb in).
  
  Fig 3: Intake Manifold Bolt Tightening Sequence
  Courtesy of GENERAL MOTORS CORP.
Route the electrical harness into position over the engine.
Install the engine harness bracket nut (1).
Tighten

Tighten the nut to 10 N.m (89 lb in).

Fig 4: Installing Engine Harness Bracket Nut
Courtesy of GENERAL MOTORS CORP.
Install the vacuum brake booster hose to the rear of the intake manifold.

Fig 5: Installing Vacuum Brake Booster Hose To Rear Of Intake Manifold
Courtesy of GENERAL MOTORS CORP.
Install the EVAP purge solenoid vent tube.

Fig 6: Installing EVAP Purge Solenoid Vent Tube
Courtesy of GENERAL MOTORS CORP.
Install the heater water shutoff valve actuator inlet hose to the intake manifold.

Fig 7: Installing Heater Water Shutoff Valve Actuator Inlet Hose To Intake Manifold
Courtesy of GENERAL MOTORS CORP.
Install the PCV hose (with valve).

Fig 8: Installing PCV Hose (With Valve)
Courtesy of GENERAL MOTORS CORP.
Install the knock sensor harness electrical connector to the intake manifold.
Connect the following electrical connectors:
- EVAP purge solenoid (1)
- Knock sensor (2)
- (MAP sensor (3)
- Main coil (4)
- Fuel injectors (5)
  
  Fig 9: Locating Electrical Connectors At Intake Manifold
  Courtesy of GENERAL MOTORS CORP.
Perform the following steps in order to connect the fuel injector electrical connectors.
1. 13.1. Install the connectors to their corresponding injectors to ensure correct reassembly.
2. 13.2. Connect the fuel injector electrical connector.
3. 13.3. Push the CPA retainer (2) on the connector in 1 click.
4. 13.4. Repeat the steps for each injector electrical connector.
Fig 10: Identifying Injector Connector CPA Retainer
Courtesy of GENERAL MOTORS CORP.
Install the harness clips to the fuel rail.
Connect the generator electrical connector.

Fig 11: Connecting Generator Electrical Connector
Courtesy of GENERAL MOTORS CORP.
Connect the following electrical connectors:
- Main coil (1)
- ETC (2)
- Fuel injectors (3)

Fig 12: Locating Main Coil, ETC & Fuel Injector Connectors

Courtesy of GENERAL MOTORS CORP.

Install the electrical harness clips to the fuel rail.
Connect the A/C compressor pressure switch electrical connector (2).
Install the harness clip to the cylinder head.

Fig 13: Connecting A/C Compressor Pressure Switch Electrical Connector
Courtesy of GENERAL MOTORS CORP.
Connect the MAF/IAT sensor electrical connector (1).
Install the air cleaner outlet duct. Refer to AIR CLEANER RESONATOR OUTLET DUCT .
Install the fuel fill cap.
Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Engine Electrical.
Use the following procedure in order to inspect for leaks:
1. 24.1. Turn the ignition ON, wit the engine OFF, for 2 seconds.
2. 24.2. Turn the ignition OFF for 10 seconds.
3. 24.3. Turn the ignition ON, with the engine OFF.
4. 24.4. Inspect for fuel leaks.
  
  Fig 14: Connecting MAF/IAT Sensor Electrical Connector
  Courtesy of GENERAL MOTORS CORP.