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Intake Manifolds: Installation

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  1. Install the new gaskets onto the cylinder heads. Install the intake manifolds. See Figure. Apply teflon sealer GM P/N 1236004 on the threads of the studs that are second to the end on both intake manifolds. There are a total of four studs that require the teflon sealer. Apply threadlocker GM P/N 12345382 on the threads of the remaining studs.
  2. Install the intake manifold studs, (from the center out) to specifications. See TORQUE SPECIFICATIONS . Install the miscellaneous brackets and fuel line brackets on the intake studs. Install the nuts for the brackets and tighten the bracket nuts to specifications. See TORQUE SPECIFICATIONS .
  3. Position the engine wiring harness. Install the electrical harness in the retaining clips. See Figure. Install the wastegate solenoid mounting bracket. See Figure. Install the wastegate solenoid mounting bracket retaining nuts and tighten the bracket nuts to specifications. See TORQUE SPECIFICATIONS .
  4. Install the wastegate solenoid. Install the wastegate solenoid retaining bolts. Tighten the wastegate solenoid bolts to specifications. See TORQUE SPECIFICATIONS . Connect the wastegate solenoid wiring harness connector. Install the vacuum hose harness.
  5. Install the glow plug relay. See Figure. Install the glow plug relay retaining nuts. Tighten the bracket nuts to specifications. See TORQUE SPECIFICATIONS .
  6. Install the glow plug relay power supply terminals. See Figure. Install the hold down nuts on the glow plug relay power supply terminals. Tighten the terminal nuts to specifications. See TORQUE SPECIFICATIONS . Connect the glow plug relay electrical connector.
  7. Install the Boost sensor gasket. Install the Boost sensor. Install the Boost sensor retaining bolts. See Figure. Tighten the terminal nuts to specifications. See TORQUE SPECIFICATIONS . Connect the Boost sensor electrical connector.
  8. Install the IAT sensor. See Figure. Tighten the IAC sensor to specifications. See TORQUE SPECIFICATIONS . Connect the Intake Air Temperature (IAT) sensor electrical connector.
  9. Install the CDR valve. Install the bracket for retaining the CDR valve to the right side lower intake manifold studs. Tighten the bracket nuts to specifications. See TORQUE SPECIFICATIONS .
  10. Install the electrical harness and retaining brackets and nuts. See Figure. Install the nuts retaining the fuel pipe brackets. Tighten the bracket nuts to specifications. See TORQUE SPECIFICATIONS .
  11. Connect the gray engine harness electrical connector. See Figure. Install the upper radiator hose. If equipped with rear Air Conditioning (A/C), install the rear A/C pipe to the A/C compressor. Tighten all compressor hose assembly retaining bolts and hose fittings to specifications. See TORQUE SPECIFICATIONS .
    12. NOTE: Always replace the O-ring between the upper intake manifold and the turbocharger.
  12. Install new upper intake manifold gaskets to the lower intake manifolds. See Figure. Install a new O-ring onto the turbocharger inlet housing. See Figure. Lightly lubricate the O-ring with clean engine oil. Install the upper intake manifold to the lower intake manifolds. Install the upper intake manifold bolts and tighten the upper intake manifold bolts to specifications. See TORQUE SPECIFICATIONS .
  13. Install a small amount of RTV sealant GM P/N 12346286 to the area on the upper tube where it joins with the lower tube. Install the upper oil level indicator tube. Install the nut retaining the oil level indicator tube to the thermostat cross over. Tighten the oil level indicator tube nut to specifications. See TORQUE SPECIFICATIONS .
  14. Install the oil level indicator. Install the bolt and the nut securing the oil level indicator tube brackets to the engine. Tighten the nut and bolt to specifications. See TORQUE SPECIFICATIONS .
  15. Fill the engine coolant. See DRAINING & FILLING COOLING SYSTEM  under ADJUSTMENTS & INSPECTIONS. Recharge the A/C system, if required. RECOVERY/EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in HVAC.
  16. Install the air intake duct from the turbocharger. Connect the battery negative cable from the battery and tighten to specifications. See TORQUE SPECIFICATIONS . Install the air cleaner assembly from the vehicle. Install the interior engine cover from the vehicle (if equipped).
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