Upper Intake Manifold Installation

Installation Procedure





1. Install the throttle body, if removed.
2. Install the MAP sensor, if removed.
3. Install the PCV valve cover, if removed, using the following procedure:
3.1. Install a NEW seal (O-ring) on the PCV valve cover.
3.2. Lubricate the seal with clean engine Oil.
3.3. Install the PCV valve cover in the upper intake manifold.
3.4. Turn and lock the PCV valve cover in position.





4. Install the power brake booster vacuum tube fitting, if removed, using the following procedure:
4.1. Install a NEW seal (O-ring) on the power brake booster vacuum tube fitting.
4.2. Lubricate the seal with clean engine Oil.
4.3. Install the power brake booster vacuum tube fitting in the upper intake manifold.
4.4. Turn and lock the power brake booster vacuum tube fitting in position.





5. Install a NEW seal on the fuel meter body assembly.
6. Lubricate the seal with clean engine Oil.





7. Install a NEW upper intake manifold to lower intake manifold gasket in the groove of the upper intake manifold.





8. Install the upper intake manifold onto the lower intake manifold.
9. If reusing the fasteners, apply threadlock GM P/N 12345382 or equivalent to the threads of the upper intake manifold attaching bolts.

Notice: Refer to Fastener Notice in Service Precautions.

10. Install the upper intake manifold attaching studs.
10.1. Tighten the upper intake manifold attaching studs on the first pass to 5 Nm (44 inch lbs.).
10.2. Tighten the upper intake manifold attaching studs on the final pass to 9 Nm (80 inch lbs.).
11. Install the fuel lines to the fuel meter body assembly.
12. Install the distributor cap.
13. Install the ignition control module.
14. Install the EVAP canister purge solenoid valve.





15. Install the accelerator control cable bracket, studs, and nuts to the intake manifold and the throttle body.
^ Tighten the accelerator control cable bracket nuts and studs to 12 Nm (106 inch lbs.).





16. Connect the A/C vacuum hose to the intake manifold.
17. Install the power brake booster vacuum hose bracket and nut to the intake manifold stud.
^ Tighten the power brake booster vacuum hose bracket nut to 11 Nm (97 inch lbs.).
18. Connect the power brake booster vacuum hose to the intake manifold.





19. Install the bracket for the engine wiring harness on the lower intake manifold stud.
20. Install the engine wiring harness bracket nut.
^ Tighten the engine wiring harness bracket nut to 12 Nm (106 inch lbs.).





21. Connect the following electrical connectors:
^ The fuel meter body assembly connector (1)
^ The EVAP canister purge solenoid valve (2)
^ The Manifold Absolute Pressure (MAP) sensor (3)





22. Connect the following electrical connectors:
^ The Throttle Position (TP) sensor (1)
^ The Idle Air Control (IAC) motor (2)
^ The Engine Coolant Temperature (ECT) gage sensor (3)
^ The A/C high pressure switch (4), if equipped





23. Connect the PCV valve hose assembly to the intake manifold and the valve rocker arm cover.
24. Install the cruise control cable, if equipped to the throttle shaft and the accelerator control cable bracket.
25. Install the accelerator control cable to the throttle shaft and the accelerator control cable bracket.





Notice: Refer to Mass Air Flow (MAF) Handling Notice in Service Precautions.

26. Install the air cleaner outlet duct to the MAF sensor.





27. Connect the IAT sensor harness connector.





28. Install the air cleaner outlet duct (2) on the throttle body assembly.
29. Tighten the retaining nut (1).
^ Tighten the nut 2 Nm (18 inch lbs.).
30. Connect the PCV tube to the air cleaner outlet duct.
31. Install the air cleaner.
32. Install the engine cover.