LEMON Manuals: Even more car manuals for everyone
Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 708 (Engine Mechanical - 3.1L (On-Vehicle)) >> Repair Instructions >> Intake Manifold Replacement - Lower >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2002 Chevrolet Malibu. However, it is still accessible from the selected car via links, so may be relevant.
  1. If removed, install the thermostat.
    Fig 1: Installing Thermostat
    G01810924Courtesy of GENERAL MOTORS CORP.
  2. If removed, install the water outlet.
    CAUTION: Refer to FASTENER NOTICE in Cautions and Notices.
  3. Install the water outlet bolts.

    Tighten 

    Tighten the water outlet bolts to 25 N.m (18 lb ft).

    Fig 2: Installing Water Outlet Bolts
    G01810925Courtesy of GENERAL MOTORS CORP.
  4. If removed, install the ECT sensor.

    Tighten 

    Tighten the ECT sensor to 23 N.m (17 lb ft).

    Fig 3: Removing ECT Sensor
    G01810926Courtesy of GENERAL MOTORS CORP.
  5. Apply 8 - 12 mm (0.08-0.11 in) bead of RTV Sealer, GM P/N 12345739 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.
    7. Fig 4: Installing Lower Intake Manifold Gaskets
    G01810927Courtesy of GENERAL MOTORS CORP.
  7. Install rocker arms and pushrods. Refer to Valve Rocker Arm and Push Rod Replacement  .
  8. Install the lower intake manifold.
    9. Fig 5: Installing Lower Intake Manifold & Bolts
    G01810928Courtesy of GENERAL MOTORS CORP.
  9. Apply sealant, GM P/N 12345382 to the threads of the lower intake manifold bolts.
    CAUTION: An oil leak may result if the vertical bolts are not tightened before the diagonal bolts.
  10. Install the vertical lower intake manifold bolts until snug.
  11. Install the diagonal lower intake manifold bolts until snug.
  12. Tighten the lower intake manifold bolts.

    Tighten See TSB For Revised Lower Intake Torque

    Fig 6: Tightening Lower Intake Manifold Bolts
    G01810929Courtesy of GENERAL MOTORS CORP.
  13. Connect the heater inlet pipe and heater hose to the lower intake manifold.
  14. Install the power steering pump to the front engine cover. Refer to POWER STEERING PUMP in Power Steering System.
    Fig 7: Connecting Heater Inlet Pipe
    G01810930Courtesy of GENERAL MOTORS CORP.
  15. Install the fuel injector rail. Refer to FUEL RAIL & INJECTORS in Engine Controls - 3.1L.
    Fig 8: Installing Fuel Injector Rail
    G01810931Courtesy of GENERAL MOTORS CORP.
  16. Connect the ECT sensor electrical connector.
    17. Fig 9: Connecting ECT Sensor Electrical Connector
    G01810932Courtesy of GENERAL MOTORS CORP.
  17. Install the upper intake manifold. Refer to Intake Manifold Replacement - Upper  .
  18. Install the valve rocker covers. Refer to Valve Rocker Arm Cover Replacement - Right (Rear)  and Valve Rocker Arm Cover Replacement - Left (Front)  .
scientia non olet · About LEMON Manuals