Intake Manifold Installation

WARNING: This page is about a different car, the 2002 GMC Yukon XL, 2002 Chevrolet Suburban, and 2002 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.

Install the splash shield.

Fig 1: Intake Manifold Splash Shield
Courtesy of GENERAL MOTORS CORP.
Ensure the splash shield (2) snap fits between the cylinder heads (1).

Fig 2: Intake Manifold Splash Shield Installation Position
Courtesy of GENERAL MOTORS CORP.
Install the new intake manifold end seals.

Fig 3: Intake Manifold End Seals
Courtesy of GENERAL MOTORS CORP.
Install the new intake manifold side gaskets onto the cylinder heads.

Fig 4: Intake Manifold Side Gaskets
Courtesy of GENERAL MOTORS CORP.
Ensure the intake manifold gasket tabs align with the hole in the head gasket.
Ensure the intake manifold gasket tabs align with the slot in the intake manifold end seals.

Fig 5: Intake Manifold Gasket Tab & Intake Manifold End Seal Slot
Courtesy of GENERAL MOTORS CORP.
Install the intake manifold onto the engine block.

Fig 6: Intake Manifold & Bolts
Courtesy of GENERAL MOTORS CORP.

NOTE: Ensure the intake manifold does not shift as the intake manifold bolts are tightened in the proper sequence. Failure to follow the entire intake manifold bolt tightening sequence exactly, may result in an oil leak and serious engine damage.

Important: The entire intake manifold tightening sequence must be promptly completed due to the anaerobic thread adhesive. The final pass of the tightening sequence must be completed before the adhesive starts to cure, or false torque readings and ineffective thread locking may result.
Apply thread adhesive GM P/N United States 12345382, GM P/N Canada 10953489, or equivalent to a minimum of eight threads of the intake manifold bolts.
Install the intake manifold bolts.

Fig 7: Intake Manifold Bolt Tightening Sequence
Courtesy of GENERAL MOTORS CORP.

NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
Tighten the intake manifold bolts in sequence, using four passes.
Tighten
- Tighten the intake manifold bolts in sequence to 5 N.m (44 lb in) on the first pass.
- Tighten the intake manifold bolts in sequence to 5 N.m (44 lb in) on the second pass. Inspect the intake manifold joints for signs of intake manifold shifting. Correct as required.
- Tighten the intake manifold bolts in sequence to 10 N.m (88 lb in) on the third pass.
- Tighten the intake manifold bolts in sequence to 12 N.m (106 lb in) on the final pass.
Important: Lubricate the injector O-ring seals with clean engine oil and install onto the spray tip end of each injector.
Install the fuel injection fuel rail.
Install the fuel injection fuel rail studs and/or bolts.
Tighten

Tighten the fuel injection fuel rail studs and/or bolts to 12 N.m (106 lb in).

Fig 8: Fuel Injection Fuel Rails
Courtesy of GENERAL MOTORS CORP.
Install the fuel pressure regulator vacuum hose.

Fig 9: Fuel Pressure Regulator Vacuum Hose
Courtesy of GENERAL MOTORS CORP.