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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1095 (Engine Mechanical - 3.4L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Intake Manifold Replacement - Lower >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 Pontiac Aztek and 2004 Buick Rendezvous. However, it is still accessible from the selected car via links, so may be relevant.
  1. If you are replacing the lower intake manifold, perform the following steps.
    2. Fig 1: Lower Intake Manifold
    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.
  2. Install the lower intake manifold gaskets.
  3. Install the push rods and tighten the valve rocker arms. Refer to Valve Rocker Arm and Push Rod Installation .
  4. With the gaskets in place apply a small drop 8-10 mm (0.31-0.39 in) of RTV sealer GM P/N 12346286 (Canadian P/N 10953472) or equivalent to the 4 corners of the intake manifold to block joint (1).
  5. 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).
  6. Install the lower intake manifold.
  7. Apply sealer GM P/N 12345382, (Canadian P/N 10953489) or the equivalent to the lower intake manifold bolt threads.
    8. Fig 2: Lower Intake Manifold Bolt Tightening Sequence
    GM187067Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
    NOTE: Maximum gasket performance is achieved when using new 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.
  8. Install the lower intake manifold bolts.

    Tighten: 

    1. Tighten the lower intake manifold bolts in sequence to 7 N.m (62 lb in) on the first pass.
    2. Tighten the lower intake manifold bolts (1, 2, 3, 4) in sequence to 13 N.m (115 lb in) on the final pass.
    3. Tighten the lower intake manifold bolts (5, 6, 7, 8) in sequence to 25 N.m (18 lb ft) on the final pass.

    9. Fig 3: Identifying Thermostat Bypass Hose
    GM261263Courtesy of GENERAL MOTORS CORP.
  9. Connect the thermostat bypass hose to the lower intake manifold pipe.
  10. Connect the inlet radiator hose to the engine. Refer to Radiator Hose Replacement - Inlet (LA1) in Engine Cooling.
  11. Connect the heater inlet pipe to the lower intake manifold. Refer to Heater Pipe Replacement - Inlet in Heating, Ventilation and Air Conditioning.
  12. Install the power steering pump to the front engine cover. Refer to Power Steering Pump Replacement (LA1 ) in Power Steering System.
    13. Fig 4: View Of Fuel Injector Rail Assembly
    GM862487Courtesy of GENERAL MOTORS CORP.
  13. Install the fuel injector rail. Refer to Fuel Rail Assembly Replacement in Engine Controls - 3.4L.
  14. Connect the fuel feed and return pipe to the fuel injector rail. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls-3.4L.
    15. Fig 5: Fuel Feed & Return Pipe Retaining Clip
    GM187065Courtesy of GENERAL MOTORS CORP.
  15. Install the fuel feed and return pipe retaining clip.
  16. 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).

    17. Fig 6: Locating Fuel Injector, Manifold Air Pressure (MAP) & ECT Wiring Harness
    GM261255Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The fuel injector wiring harness connectors must be connected to their respective fuel injectors. Failure to connect the fuel injector connectors to their respective fuel injectors may result in excessive exhaust emissions and poor engine performance.
  17. Install and connect the fuel injector, MAP and ECT wiring harness.
    18. Fig 7: ECT Sensor Electrical Connector
    GM190517Courtesy of GENERAL MOTORS CORP.
  18. Install the wiring harness to the ECT sensor.
  19. Install the engine right side valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left .
  20. Install the engine left side valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left .
  21. Install the upper intake manifold. Refer to Intake Manifold Replacement - Upper .
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