Installation Procedure

WARNING: This page is about a different car, the 2002 Oldsmobile Aurora. However, it is still accessible from the selected car via links, so may be relevant.

Lightly grease the inside edge of the rubber plenum duct.

Fig 1: Greasing Inside Edge Of Rubber Plenum Duct
Courtesy of GENERAL MOTORS CORP.
Clean any debris from the cylinder head or intake manifold.
Install the new gaskets to the intake manifold.
Important: Ensure the PCV valve hose is firmly connected to the fitting at the front of the intake manifold, prior to installation.
Place the intake manifold in position by completing the following:
1. 4.1. Position the rear of the intake manifold (1) into the plenum duct (2).
2. 4.2. Position the front of the intake manifold (1) downward on to the cylinders heads.
Fig 2: Installing Intake Manifold
Courtesy of GENERAL MOTORS CORP.
Loosely install the 10 bolts attaching the intake manifold (1) to the cylinder heads.

Fig 3: Installing Intake Manifold Bolts
Courtesy of GENERAL MOTORS CORP.

CAUTION: Refer toFASTENER NOTICE .
Tighten the intake manifold bolts in sequence (1-10).
Tighten

Tighten the intake manifold bolts to 10 N.m (89 in lbs).

Fig 4: Identifying Intake Manifold Bolt Tightening Sequence
Courtesy of GENERAL MOTORS CORP.
Ensure that the plenum duct is fully attached to the rear of the intake manifold.
Tighten

Tighten the plenum duct clamp (1) to 2.25 N.m (20 in lbs).

Fig 5: Identifying Plenum Duct Clamp
Courtesy of GENERAL MOTORS CORP.
Lubricate the intake manifold fuel injector bores with light mineral oil GM P/N 9981704, clean engine oil, or equivalent.
Important: DO NOT force the injectors into position.
Install the entire fuel rail and injector assembly into the intake manifold by pressing the fuel rail and injector simultaneously into the correct position.

Fig 6: Installing Fuel Rail & Injector Assembly
Courtesy of GENERAL MOTORS CORP.
Install the 4 bolts (1) attaching the fuel rail (2) to the intake manifold (3).
Tighten

Tighten the fuel rail bolts to 10 N.m (89 in lbs).

Fig 7: Installing Fuel Rail Bolts
Courtesy of GENERAL MOTORS CORP.
Connect the 8 electrical connectors (1) to the 8 fuel injectors (2).

Fig 8: Connecting Fuel Injectors Electrical Connectors
Courtesy of GENERAL MOTORS CORP.
Position the surge tank pipe (2) on to the fuel rail studs.
Position the engine coolant heater wire (1) on to the fuel rail studs (if equipped).
Install the 2 pushnuts.

Fig 9: Installing Engine Coolant Heater Wire Pushnuts
Courtesy of GENERAL MOTORS CORP.
Install the fuel rail bracket retaining nut (1) to the rear lift bracket.
Tighten

Tighten the fuel rail bracket retaining nut (1) to 10 N.m (89 in lbs).
Install the quick connect fittings to the fuel rail.

Fig 10: Connecting Fuel Inlet & Return Fittings & Fuel Rail Bracket Nut
Courtesy of GENERAL MOTORS CORP.
Connect the vacuum tubes (2) to the AIR solenoid.
Connect the fuel regulator vacuum tube (1).

Fig 11: Connecting Vacuum Tubes
Courtesy of GENERAL MOTORS CORP.
Connect the PCV fresh air tube (1) to the camshaft cover.

Fig 12: Connecting PCV Fresh Air Tube
Courtesy of GENERAL MOTORS CORP.
Connect the PCV dirty air tube (2) to the camshaft cover.

Fig 13: Connecting PCV Dirty Air Tube
Courtesy of GENERAL MOTORS CORP.
Connect the coil module connectors (1) to the coil modules (2) located in the camshaft covers (3).
To clean, turn the ignition switch to the ON position for 2 seconds, then turn to the OFF position for 10 seconds. Again turn to the ON position and check for fuel leaks.

Fig 14: Connecting Coil Module Connectors
Courtesy of GENERAL MOTORS CORP.
Position the intake manifold sight shield (1) to the engine.

Fig 15: Installing Fuel Injector Sight Shield

Courtesy of GENERAL MOTORS CORP.

Install the 2 intake manifold sight shield nuts (2).
Tighten

Tighten the nuts to 3 N.m (27 in lbs).