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Home >> Pontiac >> 2005 >> Grand Prix GXP >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 2 (Engine Mechanical - 3.8L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Intake Manifold Replacement - Upper >> Installation Procedure

Installation Procedure

WARNING: This page is about a different variant/trim than selected.
  1. If the manifold was replaced install the following:
    • Vacuum source manifold
    • Positive crankcase ventilation (PCV) valve
    • Manifold absolute pressure (MAP) sensor
    • Throttle body
    2. Fig 1: Upper-To-Lower Intake Manifold Carrier Gasket
    GM405818Courtesy of GENERAL MOTORS CORP.
  2. Install the upper-to-lower intake manifold carrier gasket to the upper intake manifold.
    3. Fig 2: Upper Intake Manifold Bolts & Studs
    GM910998Courtesy of GENERAL MOTORS CORP.
  3. Carefully install the upper intake manifold (5) onto the lower intake manifold. Ensure that the alignment pins in the upper intake manifold align with the holes in the lower intake manifold.
  4. Apply thread lock compound GM P/N 12345382 (Canadian P/N 10953489), or equivalent, to the threads of the bolts (1, 4) and the studs (2, 3).
    5. Fig 3: Installing Upper Intake Manifold Bolts
    GM49828Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  5. Install the upper intake manifold bolts and the studs (1-10).

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

    6. Fig 4: Fuel Rail Assembly & Fuel Injectors
    GM910936Courtesy of GENERAL MOTORS CORP.
  6. Lightly coat the fuel injectors (3) with clean engine oil.
    7. IMPORTANT: Ensure the fuel rail is fully seated in the lower intake manifold assembly.
  7. Install the fuel rail assembly (1) to the lower intake assembly.
  8. Install the fuel rail nuts (2).

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

  9. Connect the EVAP purge solenoid pipe quick connect fitting. Refer to Quick Connect Fitting(s) Service (Plastic Collar) in Engine Controls - 3.8L.
    10. Fig 5: EGR Valve Wiring Harness Heat Shield Nut & Bolt
    GM911071Courtesy of GENERAL MOTORS CORP.
  10. Install the EGR valve wiring harness heat shield (3), the nut (1) and the bolt (2).

    Tighten:  Tighten the nut and the bolt to 10 N.m (89 lb in).

    11. Fig 6: Brake Booster Hose & Vacuum Source Manifold
    GM910975Courtesy of GENERAL MOTORS CORP.
  11. Install the brake booster hose (1) to the vacuum source manifold (2).
  12. Connect the electrical connectors to the following:
    • Mass air flow (MAF) sensor
    • Manifold absolute pressure (MAP) sensor
    • EVAP purge solenoid
    • Electronic throttle control (ETC)
  13. Install the right spark plug wires to the ignition control module and the upper intake manifold. Refer to Spark Plug Wire Replacement in Engine Controls - 3.8L.
  14. Install the air cleaner intake duct. Refer to Air Cleaner Intake Duct Replacement in Engine Controls - 3.8L.
  15. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (L26)  or Fuel Injector Sight Shield Replacement (L32) .
  16. Fill the cooling system. Refer to Draining and Filling Cooling System (L26 and L32) in Engine Cooling.
  17. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (RPOs L26/L32) in Engine Electrical.
  18. Inspect for fluid or vacuum leaks.
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