Installation Procedure
WARNING: This page is about a different car, the 2002 Oldsmobile Aurora. However, it is still accessible from the selected car via links, so may be relevant.
Important: If you did NOT replace the intake manifold skip the intake manifold assembly.
- If necessary, assemble the intake manifold. Refer to INTAKE MANIFOLD ASSEMBLE .
- Install the intake manifold.
- Connect the throttle body heater hose to the water crossover feed tube (1).
- Install the hose clamp.
- Loosely install the intake manifold bolts.
CAUTION: Refer to FASTENER NOTICE in Cautions and Notices.
- Tighten the intake manifold bolts in sequence (1-8).
Tighten
Tighten the intake manifold bolts to 10 N.m (89 lb in).
- Inspect the fuel injector O-rings (2) for misalignment or damage. Replace the O-rings if necessary.
- Lubricate the intake manifold fuel injector bores with light mineral oil GM P/N 9981704, clean engine oil, or equivalent.
- Install the fuel rail (1) and fuel injectors (2) by aligning the fuel injectors with their respective ports and pressing the 4 fuel rail snap-lock connectors into the intake manifold until they lock in place. DO NOT apply excessive pressure to the fuel rail in place. The need for excessive pressure may be caused by misalignment of a fuel injector and could cause damage to the seal or intake manifold.
Important: The EGR valve outlet pipe incorporates a crush seal connection at the water crossover. The EGR valve outlet pipe must be replaced if disconnected from the water crossover.
- Install the NEW EGR outlet pipe with NEW O-ring seal.
- Install the EGR outlet pipe-to-intake manifold bolts.
Tighten
Tighten the EGR outlet pipe-to-intake manifold bolts to 10 N.m (89 lb in).
- Install the EGR outlet pipe-to-water crossover bolts.
Tighten
Tighten the EGR outlet pipe-to-water crossover bolts to 24 N.m (18 lb ft).
- Install the both feed tubes (1, 2) to the camshaft covers and intake manifold.
- Connect the brake booster vacuum hose to the brake booster.
- Connect the fuel pressure regulator vacuum tube (1) to the regulator (2) and the throttle body (3).
- Connect the A/C vacuum hose to the intake manifold.
- Install the engine wiring harness and channel. Refer to COMPONENT LOCATIONS in Engine Controls-3.5L.
- Install the engine wiring harness channel bolts to the camshaft covers. Refer to COMPONENT LOCATIONS
in Engine Controls-3.5L.
Tighten
Tighten the engine wiring harness channel bolts to 10 N.m (89 lb in).
- Connect the surge tank inlet pipe retainer to the fuel injector rail.
- Connect the engine wiring harness connectors to the following components:
Refer to COMPONENT LOCATIONS in Engine Controls-3.5L.
- Throttle position (TP) sensor
- Idle air control (IAC) valve
- EVAP canister purge solenoid
- Manifold absolute pressure (MAP) sensor
- Connect the fuel injector wiring harness connectors. Refer to COMPONENT LOCATIONS in Engine Controls-3.5L.
- Connect the throttle body coolant hoses to the throttle body.
- Connect the accelerator cable to the throttle body and accelerator cable bracket. Refer to THROTTLE BODY in Engine Controls-3.5L.
- Connect the cruise control cable to the throttle body. Refer to CRUISE CONTROL CABLE (4.0L V8) or CRUISE CONTROL CABLE (3.5L V6) in Cruise Control.
- Connect the fuel lines to the throttle body.
- Connect the fuel vapor line to the EVAP canister purge solenoid. Refer to EVAP CANISTER PURGE SOLENOID in Engine Controls-3.5L.
- Install the fuel injector sight shield (3). Refer to Fuel Injector Sight Shield Replacement .
- Carefully connect the throttle body air inlet duct to the throttle body.
- Fill the cooling system with engine coolant. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
- Connect the battery ground (negative) cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PRO in Engine Electrical.