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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1401 (Engine Mechanical - 3.8L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Intake Manifold Replacement - Lower (L36) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2003 Buick Regal. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  1. If removed, install the ECT sensor.

    Tighten 

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

  2. If removed, install the thermostat, the gasket, and the water outlet housing.
  3. Install the water outlet housing bolt and the stud.

    Tighten 

    Tighten the bolt and the stud to 27 N.m (20 lb ft).

    Fig 1: Installing Thermostat, Gasket, & Water Outlet Housing
    G01968433Courtesy of GENERAL MOTORS CORP.
  4. Install the lower intake manifold gaskets.
    Fig 2: Installing Lower Intake Manifold Gaskets
    G01968434Courtesy of GENERAL MOTORS CORP.
  5. Apply sealer GM P/N 12346286, (Canadian P/N 10953472) or equivalent to the ends of the intake manifold seals.
  6. Install the lower intake manifold seals
    Fig 3: Installing Lower Intake Manifold Seals
    G01968435Courtesy of GENERAL MOTORS CORP.
    NOTE: The two bolts which fasten the lower intake manifold to the cylinder head are accessible only after the upper intake is removed. The bolts are located in the right front and left rear corners of the lower intake manifold. Remove the upper intake manifold to service the lower intake.
  7. Install the lower intake manifold.
    Fig 4: Installing Lower Intake Manifold & Bolts
    G01968436Courtesy of GENERAL MOTORS CORP.
  8. Install the lower intake manifold bolts (1-12). Apply thread lock compound GM P/N 12345493, (Canadian P/N 10953488) or equivalent to the two hidden bolts and ensure they are installed.

    Tighten 

    Tighten the lower intake manifold bolts in sequence to 15 N.m (11 lb ft).

    Fig 5: Tightening Sequence Of Lower Intake Manifold Bolts
    G01968437Courtesy of GENERAL MOTORS CORP.
  9. Install the generator brace bracket.
    Fig 6: Installing Generator Brace Bracket & Bolts
    G01968438Courtesy of GENERAL MOTORS CORP.
  10. Install the generator brace bracket bolts.

    Tighten 

    Tighten the bolts to 50 N.m (37 lb ft).

  11. Connect the ECT sensor electrical connector.
    Fig 7: Connecting ECT Sensor Electrical Connector
    G01968439Courtesy of GENERAL MOTORS CORP.
  12. Install the radiator inlet hose to the water outlet housing. Refer to RADIATOR HOSE REPLACEMENT - INLET (3.8L) in Engine Cooling.
    Fig 8: Installing Radiator Inlet Hose To Water Outlet Housing
    G01968440Courtesy of GENERAL MOTORS CORP.
  13. Install the EGR outlet pipe to the lower intake manifold.
  14. Install the EGR outlet pipe bolt to the lower intake manifold.

    Tighten 

    Tighten the bolt to 29 N.m (21 lb ft).

    Fig 9: Installing EGR Outlet Pipe To Lower Intake Manifold
    G01968441Courtesy of GENERAL MOTORS CORP.
  15. Install the drive belt tensioner. Refer to DRIVE BELT TENSIONER REPLACEMENT  .
    Fig 10: Installing Thermostat Water Bypass Pipes
    G01968442Courtesy of GENERAL MOTORS CORP.
  16. Install the generator brace.
  17. Install the upper intake manifold. Refer to INTAKE MANIFOLD REPLACEMENT - UPPER  .
  18. Install the evaporative emissions (EVAP) canister purge solenoid.
    Fig 11: Installing Evaporative Emissions Canister Purge Solenoid
    G01968443Courtesy of GENERAL MOTORS CORP.
  19. Inspect for fluid or vacuum leaks.
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