Intake Manifold Installation

Special Tools

• EN-45059  Angle Meter
• EN-50790  HP Fuel Pump Installation Alignment Gauge

For equivalent regional tools, refer to Special Tools .

Fig 1: Intake Manifold And Gasket
Courtesy of GENERAL MOTORS COMPANY
1. Install a NEW gasket (1) on the intake manifold (3). Install the intake manifold and hand start the intake manifold bolts (2, 4).
Fig 2: Intake Manifold Bolt tightening Sequence
Courtesy of GENERAL MOTORS COMPANY
CAUTION:

Refer to Fastener Caution .

2. tighten the bolts and nuts in sequence twice to 12 N.m (106 lb in).
Fig 3: MAP Sensor And Bolt
Courtesy of GENERAL MOTORS COMPANY
3. Install the MAP sensor (1) and bolt (2). tighten the bolt to 5 N.m (44 lb in).
Fig 4: View Of HP Fuel Pump Installation Alignment Gauge
Courtesy of GENERAL MOTORS COMPANY
NOTE:

The camshaft must be in the base circle position before the high pressure fuel pump is installed.

4. Use the EN-50790  alignment gauge (2) to ensure that the camshaft lobe is in the base circle position. At base circle position, the tool will be flush with the head (1).
Fig 5: High Pressure Fuel Pump Assembly
Courtesy of GENERAL MOTORS COMPANY
5. Lubricate the high pressure fuel pump cylinder head bore with clean, silicone-free 5W30 engine oil.
NOTE:

Ensure that the high pressure fuel pump roller lifter is oriented properly, and the camshaft is at base circle.

6. Lubricate the high pressure fuel pump roller lifter (1) with 5W30 engine oil and install into the cylinder head bore.
7. Lubricate the NEW O-ring (3) with one drop of clean engine oil. Install the NEW fuel pump housing O-ring (3).
NOTE:

Ensure the fuel pump housing gasket (2) is properly aligned with the tab upward at the 2 O'clock position.

8. Install the NEW fuel pump housing gasket (2).
9. Install the fuel pump assembly (4).
CAUTION:

Alternately hand-tighten the fuel pump bolts one turn at a time until the pump is fully seated. Trying to draw down the pump without even side-to-side tightening may result in pump plunger damage.

10. Apply theadlocker to the bolts, refer to Adhesives, Fluids, Lubricants, and Sealers .
CAUTION:

This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component. Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.

11. Hand start the NEW fuel pump bolts evenly. tighten the fuel pump bolts evenly to 8 N.m (71 lb in) plus 50 degrees using the EN-45059  meter.
12. Hand start both ends of the NEW fuel feed intermediate pipe (5).
    1. tighten the fitting nut to the fuel rail to 15 N.m (11 lb ft).
    2. tighten the fitting nut to the fuel pump to 15 N.m (11 lb ft).
    3. tighten the fitting nut to the fuel rail a final pass to 30 N.m (22 lb ft).
    4. tighten the fitting nut to the fuel pump a final pass to 30 N.m (22 lb ft).
WARNING:

The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.

13. Install the fuel pump insulator (6).
Fig 6: Fuel Pump Cover Bolts And Cover
Courtesy of GENERAL MOTORS COMPANY
14. Install the fuel pump cover and bolts. tighten the bolts to 10 N.m (89 lb in).
Fig 7: Throttle Body Bolts
Courtesy of GENERAL MOTORS COMPANY
15. Install a new throttle body gasket (3).
16. Install the throttle body (2).
17. Install the throttle body bolts (1) and tighten to 10 N.m (89 lb in).
Fig 8: EVAP Canister Valve
Courtesy of GENERAL MOTORS COMPANY
NOTE:

Ensure the quick-connect is clean and free of debris. The latch should move freely prior to installation.

18. Install the EVAP canister valve (1) and connect the EVAP canister valve tube.