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Home >> Chevrolet >> 2002 >> Impala Police >> Repair and Diagnosis >> External Pages >> Different car >> Section 567 (Engine Mechanical - 3.4L V6 - VIN (E) (La1)) >> Repair Instructions >> On-Vehicle Repair instructions >> Intake Manifold Replacement - Lower >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2003 Chevrolet Monte Carlo and 2003 Chevrolet Impala. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Thermostat
    GM190521Courtesy of GENERAL MOTORS CORP.
  1. Install the thermostat.
    2. Fig 2: Water Outlet & Bolts
    GM190520Courtesy of GENERAL MOTORS CORP.
  2. Install the water outlet.
    3. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the water outlet bolts.

    Tighten:  Tighten the bolts to 25 N.m (18 lb ft).

    4. Fig 3: ECT Sensor
    GM190519Courtesy of GENERAL MOTORS CORP.
  4. Install the ECT sensor. Refer to ENGINE COOLANT TEMPERATURE SENSOR .
    5. Fig 4: Lower Intake Manifold & Sealant Locations
    GM843417Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: All gasket-mating surfaces need to be free of oil, and foreign material. Use GM P/N 12346139 (Canadian P/N 10953463) or equivalent to clean surfaces.
    NOTE: When replacing lower intake manifold gasket, a revised intake manifold gasket has been introduced by manufacturer. This new design gasket helps resolve issues related to intake manifold oil/coolant leaks. The gasket requires a revised torque specification and procedure in addition to the use of NEW revised intake manifold bolts. Please review TSB ENGINE OIL OR COOLANT LEAK (INSTALL NEW INTAKE MANIFOLD GASKET) for complete information.
  5. Install the lower intake manifold gaskets.
  6. With gaskets in place apply a small drop 8-10 mm (0.31-0.39 in) of RTV Sealer, GM P/N 12346141 (Canadian P/N 10953433) or the equivalent, to the 4 corners if the intake manifold to block joint (1).
  7. Connect the 2 small drops with a bead of RTV Sealer that is between 8-10 mm (0.31-0.39 in) wide and 3.0-5.0 mm (0.12-0.20 in) thick (2).
  8. Install the valve rocker arms and pushrods. Refer to Valve Rocker Arm and Push Rod Replacement .
    9. Fig 5: Lower Intake Manifold Bolt Tightening Sequence
    GM187067Courtesy of GENERAL MOTORS CORP.
    NOTE: Maximum gasket performance is achieved when using fasteners, which contain a thread locking patch. If the fasteners are not replaced, a thread locking chemical must be applied to the fastener threads. Failure to replace the fasteners or apply a thread locking chemical MAY reduce gasket sealing capability.
    IMPORTANT: All lower intake manifold bolts need to be cleaned, free of any foreign material, and reused only if new bolts are unavailable. Use GM P/N 12345382 (Canadian P/N 10953489) or equivalent and apply to the old intake manifold bolt threads.
    IMPORTANT: Manufacturer recommends the center bolts be fully torqued before the diagonal bolts to assure proper seal ability.
    IMPORTANT: Lower intake manifold bolts in location 6 and 7 should be torqued to specification using a crows foot type tool.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  9. Install the lower intake manifold.

    Install the lower intake manifold bolts.

    Tighten: See TSB For Revised Lower Intake Torque

    10. Fig 6: Thermostat Bypass Hose At Thermostat Bypass Pipe & Lower Intake Manifold Pipe
    GM190522Courtesy of GENERAL MOTORS CORP.
  10. Install the thermostat bypass hose to the thermostat bypass pipe and lower intake manifold pipe.
  11. Install the radiator inlet hose to the engine. Refer to Radiator Hose Replacement - Inlet (3.4L) in Engine Cooling.
    12. Fig 7: View Of Heater Inlet Pipe & Nut
    GM523326Courtesy of GENERAL MOTORS CORP.
  12. Install the heater inlet pipe.
  13. Install the heater inlet pipe nut.

    Tighten:  Tighten the heater inlet pipe nut to 25 N.m (18 lb ft).

  14. Install the power steering pump to the front engine cover. Refer to Power Steering Pump Replacement (3.4L) in Power Steering System.
    15. Fig 8: View Of Fuel Injector Rail Assembly
    GM862487Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Do not press on the fuel pressure regulator valve when installing the fuel injector rail assembly.
  15. Install the fuel injector rail assembly.
    1. Install the fuel injector O-ring using GM P/N 12345616 (Canadian P/N 993182), or equivalent.
    2. Install the injector nozzles into the lower intake manifold injector bores.
    3. Press on the injector rail using the palms of both hands until the injectors are fully seated.
  16. Install the fuel injector rail bolts.

    Tighten:  Tighten the injector rail bolts to 10 N.m (89 lb in).

    17. Fig 9: Fuel Feed & Return Pipe Retaining Clip
    GM187065Courtesy of GENERAL MOTORS CORP.
  17. Install the fuel feed and return pipe retaining clip.
  18. Install the fuel feed and return pipe retaining clip bolt

    Tighten:  Tighten the fuel feed and return pipe retaining clip bolt to 8 N.m (71 lb in).

    19. Fig 10: Fuel Injector & MAP Sensor Wiring Harnesses
    GM190518Courtesy of GENERAL MOTORS CORP.
  19. Install and connect the fuel injector and the MAP sensor wiring harnesses.
    20. Fig 11: ECT Sensor Electrical Connector
    GM190517Courtesy of GENERAL MOTORS CORP.
  20. Connect the ECT sensor electrical connector.
  21. Install the right valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Right .
  22. Install the left valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left .
  23. Install the upper intake manifold. Refer to Intake Manifold Replacement - Upper .
  24. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  25. Inspect for leaks.
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