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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1400 (Engine Mechanical - 3.1L V6 - VIN (J)) >> Repair Instructions >> On-Vehicle repair Instructions >> Intake Manifold Replacement - Lower >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2003 Buick Century. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the thermostat.
    Fig 1: Installing Thermostat
    G01967872Courtesy of GENERAL MOTORS CORP.
  2. Install the water outlet.
    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).

    Fig 2: Installing Water Outlet & Bolts
    G01967873Courtesy of GENERAL MOTORS CORP.
  4. Install the ECT sensor.

    Tighten 

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

    Fig 3: Installing Engine Coolant Temperature Sensor
    G01967874Courtesy of GENERAL MOTORS CORP.
  5. Apply 8-12 mm (0.08-0.11 in) bead of RTV Sealer, GM P/N 12346286 (Canadian P/N 10953472) or equivalent, on each ridge where front and rear of the lower intake manifold contact the engine block (1).
  6. Install the lower intake manifold gaskets.
    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.
  7. Install the valve rocker arms and pushrods. Refer to VALVE ROCKER ARM AND PUSH ROD REPLACEMENT  .
    Fig 4: Installing Lower Intake Manifold Gaskets
    G01967875Courtesy of GENERAL MOTORS CORP.
  8. Install the lower intake manifold.
  9. Apply sealant, GM P/N 12345382 (Canadian P/N 10953489) to the threads of the bolts.
    Fig 5: Installing Lower Intake Manifold & Bolts
    G01967876Courtesy of GENERAL MOTORS CORP.
    NOTE: An oil leak may result if the vertical bolts are not tightened before the diagonal bolts.
  10. Install the lower intake manifold bolts (1, 2).

    Tighten 

    1. 10.1. Tighten the vertical lower intake manifold bolts (1) to 7 N.m (62 lb in).
    2. 10.2. Tighten the diagonal lower intake manifold bolts (2) to 7 N.m (62 lb in).
    3. 10.3. Tighten the vertical lower intake manifold bolts (1) to 13 N.m (115 lb in).
    4. 10.4. Tighten the diagonal lower intake manifold bolts (2) to 13 N.m (115 lb in).
      Fig 6: Installing Vertical & Diagonal Lower Intake Manifold Bolts
      G01967877Courtesy of GENERAL MOTORS CORP.
  11. Install the thermostat bypass hose to the thermostat bypass pipe and lower intake manifold pipe.
  12. Install the heater inlet pipe nut.

    Tighten 

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

  13. Install the radiator inlet hose to the engine. Refer to RADIATOR HOSE REPLACEMENT - INLET (3.1L) in Engine Cooling.
    Fig 7: Installing Thermostat Bypass Hose To Thermostat Bypass Pipe And Lower Intake Manifold Pipe
    G01967878Courtesy of GENERAL MOTORS CORP.
  14. Install the heater inlet pipe and heater hose to the lower intake manifold.
  15. Install the power steering pump to the front engine cover. Refer to POWER STEERING PUMP REPLACEMENT (3.1L) in Power Steering System.
    Fig 8: Installing Heater Inlet Pipe & Heater Hose To Lower Intake Manifold
    G01967879Courtesy of GENERAL MOTORS CORP.
  16. Install the fuel injector rail. Refer to FUEL RAIL & INJECTORS in Removal & Installation.
    Fig 9: Installing Fuel Injector Rail
    G01967880Courtesy of GENERAL MOTORS CORP.
  17. Install the fuel return pipe to the fuel injector rail. Refer to FUEL LINE DISCONNECT FITTINGS in Removal & Installation.
    Fig 10: Installing Fuel Return Pipe To Fuel Injector Rail
    G01967881Courtesy of GENERAL MOTORS CORP.
  18. Install the fuel feed pipe to the fuel injector rail. Refer to FUEL LINE DISCONNECT FITTINGS in Removal & Installation.
    Fig 11: Installing Fuel Feed Pipe To Fuel Injector Rail
    G01967882Courtesy of GENERAL MOTORS CORP.
  19. Install the fuel pipe clip.
    Fig 12: Installing Fuel Pipe Clip
    G01967883Courtesy of GENERAL MOTORS CORP.
  20. Install the fuel pipe clip bolt.

    Tighten 

    Tighten the bolt to 8 N.m (71 lb in).

    Fig 13: Installing Fuel Pipe Clip Bolt
    G01967884Courtesy of GENERAL MOTORS CORP.
  21. Install and connect the fuel injector and the MAP sensor wiring harnesses.
    Fig 14: Connecting Fuel Injector & MAP Sensor Wiring Harnesses
    G01967885Courtesy of GENERAL MOTORS CORP.
  22. Connect the ECT sensor electrical connector.
    Fig 15: Connecting ECT Sensor Electrical Connector
    G01967886Courtesy of GENERAL MOTORS CORP.
  23. Install the right valve rocker arm cover. Refer to VALVE ROCKER ARM COVER REPLACEMENT - RIGHT  .
  24. Install the left valve rocker arm cover. Refer to VALVE ROCKER ARM COVER REPLACEMENT - LEFT  .
  25. Install the upper intake manifold. Refer to INTAKE MANIFOLD REPLACEMENT - UPPER  .
  26. Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE Battery.
  27. Inspect for leaks.
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