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Home >> Hummer >> 2008 >> H2 4D Utility Wagon >> Repair and Diagnosis >> External Pages >> Different car >> Section 525 (Engine Mechanical - Hybrid (LZ1) - Repair Instructions - On Vehicle) >> Repair Instructions - On Vehicle >> Intake Manifold Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2012 GMC Yukon, 2012 Chevrolet Tahoe, and 2012 Cadillac Escalade. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Fuel Rail & Bolts
    GM1697066Courtesy of GENERAL MOTORS COMPANY
  1. Install NEW fuel injector lower O-ring seals onto the injectors.
  2. Lubricate the NEW O-ring seals with clean engine oil.
    3. NOTE:

    Push down firmly on both sides of the rail until all the injectors have been seated into their bores.

  3. Install the fuel rail.
    4. CAUTION:

    Refer to Fastener Caution .

  4. Install the fuel rail bolts.

    Tighten 

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

    5. Fig 2: View Of Throttle Body, Gasket & Bolts/Nuts
    GM1697064Courtesy of GENERAL MOTORS COMPANY
  5. Install a NEW throttle body gasket to the intake manifold.
  6. Install the throttle body.
  7. Install the throttle body bolts/nuts.

    Tighten 

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

    8. Fig 3: View Of EVAP Tube & Purge Solenoid
    GM1697062Courtesy of GENERAL MOTORS COMPANY
  8. Install the EVAP tube and purge solenoid.
  9. Install the EVAP canister purge solenoid to the fuel rail bracket and engage the retainer.
  10. Connect the EVAP tube quick connect fitting at the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service .
    11. Fig 4: View Of MAP Sensor & Retainer
    GM1697060Courtesy of GENERAL MOTORS COMPANY
  11. Lubricate the MAP sensor seal with clean engine oil.
  12. Install the MAP sensor with a new seal.
  13. Install the MAP sensor retainer.
    14. Fig 5: View Of Upper Intake Manifold Cover & Nut
    GM1697057Courtesy of GENERAL MOTORS COMPANY
  14. Install the upper intake manifold cover.
  15. Install the upper intake manifold cover nut until snug.
    16. Fig 6: View Of Intake Manifold-To-Cylinder Head Gasket
    GM1277097Courtesy of GENERAL MOTORS COMPANY
  16. Install NEW intake manifold gaskets (514) to the intake manifold.
  17. Remove the covers from the cylinder head passages.
    18. Fig 7: Intake Manifold
    GM1401989Courtesy of GENERAL MOTORS COMPANY
  18. Install the intake manifold (500).
  19. Apply a 5 mm (0.20 in) band of threadlock GM P/N 12345382 (Canadian P/N 10953489) to the threads of the intake manifold bolts (512). Refer to Adhesives, Fluids, Lubricants, and Sealers .
    20. NOTE:

    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.

  20. Install the intake manifold bolts (512) finger tight.
    21. Fig 8: Identifying Intake Manifold Bolt Tightening Sequence
    GM1552512Courtesy of GENERAL MOTORS COMPANY
  21. 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).
    22. Fig 9: View Of PCV Hose
    GM1696791Courtesy of GENERAL MOTORS COMPANY
  22. Position and install the PCV hose to the intake manifold fitting.
    23. Fig 10: View Of EVAP Canister Purge Tube & Quick Connect Fitting
    GM1696917Courtesy of GENERAL MOTORS COMPANY
  23. Connect the fuel feed line quick connect fitting (2) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  24. Connect the EVAP canister purge tube (1) quick connect fitting to the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service .
    25. Fig 11: View Of Engine Wiring Harness, Clip, Bolt & Connector
    GM1696914Courtesy of GENERAL MOTORS COMPANY
  25. Untie the engine harness branches from the cowl panel and position over the engine.
  26. Connect the engine harness electrical connector (2) to the ECT sensor.
  27. 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).

  28. Connect the generator control module electrical connector.
    29. Fig 12: View Of CPA Retainer, Engine Harness Electrical Connectors & Harness Clips
    GM1696893Courtesy of GENERAL MOTORS COMPANY
  29. Connect the engine harness electrical connectors (5) to the right side fuel injectors.
  30. Install the engine harness clip (4) to the ignition coil bracket stud.
  31. Connect the engine harness electrical connector (3) to the throttle actuator.
  32. Connect the engine harness electrical connector (2) to the ignition coil harness electrical connector.
  33. Install the CPA retainer (1).
    34. Fig 13: Identifying Engine Harness, Connectors & Retainers
    GM1964794Courtesy of GENERAL MOTORS COMPANY
  34. Install the engine harness clip (4) to the ignition coil bracket stud.
  35. Connect the engine harness electrical connectors (3) to the left side fuel injectors.
  36. Connect the engine harness electrical connector (2) to the ignition coil harness electrical connector.
  37. Install the CPA retainer (1).
    38. Fig 14: Identifying Engine Harness & Retainer Nuts
    GM1964656Courtesy of GENERAL MOTORS COMPANY
  38. Connect the engine wiring harness electrical connector (3) to the MAP sensor.
  39. Connect the engine harness electrical connector (2) to the EVAP canister purge solenoid.
  40. Install the engine harness retainer to the stud and locator pin.
  41. Install the engine harness retainer nut (1).

    Tighten 

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

  42. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement .
  43. Connect the battery ground cable. Refer to Battery Negative Cable Disconnection and Connection .
  44. Perform the High Voltage Service connect. Refer to High Voltage Enabling .
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