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Home >> Hummer >> 2008 >> H2 4D Utility Wagon >> Repair and Diagnosis >> External Pages >> Different car >> Section 220 (Engine Mechanical - 4.8L, 5.3L, 6.0L Or 6.2L (2 Of 5)) >> On-Vehicle Repair Instructions (1 Of 2) >> Intake Manifold Replacement (RPO L92 - First Design) >> Installation Procedure

Installation Procedure

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    Fig 1: View Of Brake Booster Vacuum Hose Nipple
    GM1697067Courtesy of GENERAL MOTORS CORP.
  1. If the intake manifold was replaced perform the following steps, otherwise proceed to step  21.
    2. IMPORTANT: Evenly push in the RED collar in order to install the nipple.
  2. Install the brake booster vacuum hose nipple to the NEW intake manifold.
    3. Fig 2: View Of Fuel Rail & Bolts
    GM1697066Courtesy of GENERAL MOTORS CORP.
  3. Install NEW fuel injector lower O-ring seals onto the injectors.
  4. Lubricate the NEW O-ring seals with clean engine oil.
    5. IMPORTANT: Push down firmly on both sides of the rail until all the injectors have been seated into their bores.
  5. Install the fuel rail.
    6. NOTE: Refer to Fastener Notice .
  6. Install the fuel rail bolts.

    Tighten:  Tighten the bolts to 10 N.m (89 lb in).

    7. Fig 3: View Of Throttle Body, Gasket & Bolts/Nuts
    GM1697064Courtesy of GENERAL MOTORS CORP.
  7. Install a NEW throttle body gasket to the intake manifold.
  8. Install the throttle body.
  9. Install the throttle body bolts/nuts.

    Tighten:  Tighten the bolts/nuts to 10 N.m (89 lb in).

    10. Fig 4: View Of EVAP Tube & Purge Solenoid
    GM1697062Courtesy of GENERAL MOTORS CORP.
  10. Install the EVAP tube and purge solenoid.
  11. Install the EVAP canister purge solenoid to the fuel rail bracket and engage the retainer.
  12. Connect the EVAP tube quick connect fitting at the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service .
    13. Fig 5: View Of MAP Sensor & Retainer
    GM1697060Courtesy of GENERAL MOTORS CORP.
  13. Lubricate the MAP sensor seal with clean engine oil.
  14. Install the MAP sensor.
  15. Install the MAP sensor retainer.
    16. Fig 6: View Of Upper Intake Manifold Cover & Nut
    GM1697057Courtesy of GENERAL MOTORS CORP.
  16. Install the upper intake manifold cover.
  17. Install the upper intake manifold cover nut until snug
    18. Fig 7: View Of Vacuum Brake Booster Hose
    GM1697051Courtesy of GENERAL MOTORS CORP.
  18. Install the brake booster vacuum hose to the intake manifold nipple.
  19. Position the brake booster vacuum hose clamp at the intake manifold.
  20. Secure the brake booster vacuum hose to the intake manifold.
    21. Fig 8: View Of Intake Manifold Gasket
    GM1277097Courtesy of GENERAL MOTORS CORP.
  21. Install NEW intake manifold gaskets (514) to the intake manifold.
  22. Remove the covers from the cylinder head passages.
    23. Fig 9: View Of Intake Manifold
    GM1401989Courtesy of GENERAL MOTORS CORP.
  23. Install the intake manifold (500).
    24. IMPORTANT: The aid of an assistant may be helpful in holding the engine harness up out of the way so the upper intake manifold cover does not get caught against the engine harness.
  24. Tighten the intake manifold bolts (512) until snug.
    25. Fig 10: Identifying Intake Manifold Bolt Tightening Sequence
    GM63222Courtesy of GENERAL MOTORS CORP.
  25. Tighten the intake manifold bolts to specifications.

    Tighten: 

    • Tighten the bolts a first pass in the sequence shown to 5 N.m (44 lb in).
    • Tighten the bolts a final pass in the sequence shown to 10 N.m (89 lb in).

    26. Fig 11: View Of PCV Hose
    GM1696791Courtesy of GENERAL MOTORS CORP.
  26. Position and install the PCV hose to the intake manifold fitting.
    27. Fig 12: View Of EVAP Canister Purge Tube & Quick Connect Fitting
    GM1696917Courtesy of GENERAL MOTORS CORP.
  27. Connect the fuel feed line quick connect fitting (2) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  28. Connect the EVAP canister purge tube (1) quick connect fitting to the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service .
    29. Fig 13: View Of Brake Booster Vacuum Hose & Booster Fitting
    GM1696916Courtesy of GENERAL MOTORS CORP.
  29. Unsecure the brake booster vacuum hose from the intake manifold.
  30. Install the brake booster vacuum hose to the booster fitting.
  31. Position the brake booster vacuum hose clamp at the booster.
    32. Fig 14: View Of Engine Wiring Harness, Clip, Bolt & Connector
    GM1696914Courtesy of GENERAL MOTORS CORP.
  32. Untie the engine harness branches from the cowl panel and position over the engine.
  33. Connect the engine harness electrical connector (2) to the ECT sensor.
  34. Position the engine harness clip (1) to the generator bracket and install the bolt (3).

    Tighten:  Tighten the bolt to 9 N.m (80 lb in).

    35. Fig 15: View Of CPA Retainer, Engine Harness Electrical Connectors & Harness Clips
    GM1696893Courtesy of GENERAL MOTORS CORP.
  35. Connect the engine harness electrical connectors (7) to the right side fuel injectors.
  36. Install the engine harness clip (6) to the ignition coil bracket stud.
  37. Install the engine harness clip (4) to the generator battery jumper cable.
  38. Connect the engine harness electrical connector (3) to the throttle actuator.
  39. Connect the engine harness electrical connector (1) to the ignition coil harness electrical connector.
  40. Install the CPA retainer (2).
    41. Fig 16: View Of CPA Retainer, Electrical Connectors & Engine Harness Clips
    GM1696892Courtesy of GENERAL MOTORS CORP.
  41. Install the engine harness clip (4) to the ignition coil bracket stud.
  42. Connect the engine harness electrical connectors (3) to the left side fuel injectors.
  43. Connect the engine harness electrical connector (1) to the ignition coil harness electrical connector.
  44. Install the CPA retainer (1).
    45. Fig 17: View Of Engine Harness Retainer Nut & Electrical Connectors
    GM1696891Courtesy of GENERAL MOTORS CORP.
  45. Connect the engine wiring harness electrical connector (4) to the MAP sensor.
  46. Connect the engine harness electrical connector (2) to the EVAP canister purge solenoid.
  47. Install the engine harness retainer to the stud and locator pin.
  48. Install the engine harness retainer nut (1).

    Tighten:  Tighten the nut to 5 N.m (44 lb in).

  49. Install the generator. Refer to Generator Replacement .
  50. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement .
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