GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Monte Carlo 🢒 Engine 🢒 Engine Mechanical - 3.8L 🢒 Upper Intake Manifold Installation

    Object Number: 42225 Size: SH
  1. Install the upper intake manifold gasket.
  2. Install the upper intake manifold.

    3. Object Number: 49828 Size: SH

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  3. Install the upper intake manifold bolts.

    4. Tighten
    Tighten the upper intake manifold bolts in sequence to 10 N·m (89 lb in).


    Object Number: 153566 Size: SH

    Important: Double check the cleanliness of the throttle body to upper intake surfaces prior to assembly.

  4. Install the throttle body gasket.
  5. Install the throttle body.
  6. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) to the threads.
  7. Install the throttle body nuts.

    8. Tighten
    Tighten the throttle body nuts to 10 N·m (89 lb in).


    Object Number: 211908 Size: SH
  8. Install the engine wiring harness heat shield.
  9. Install the engine wiring harness heat shield bolt and nut.

    10. Tighten
    Tighten the engine wiring harness heat shield bolt and nut to 10 N·m (89 lb in).


    Object Number: 192745 Size: SH
  10. Install the accelerator control cable bracket.
  11. Install the accelerator control cable bracket bolts.

    12. Tighten
    Tighten the accelerator control cable bracket bolts to 16 N·m (12 lb ft).


    Object Number: 153568 Size: SH

    Important: Do not use the fuel injector O-ring seals twice. Install NEW fuel injector O-ring seals during assembly.

  12. Install the fuel injector rail.
  13. Install the fuel injector rail nuts.

    14. Tighten
    Tighten the fuel injector rail nuts to 10 N·m (89 lb in).


    Object Number: 638520 Size: SH
  14. Install the ignition control module assembly.
  15. Install the ignition control module assembly bracket nuts.

    16. Tighten
    Tighten the ignition control module assembly bracket nuts to 50 N·m (37 lb ft).

  16. Connect the ignition control module connector to the ignition control module assembly.
  17. Connect the ignition wires to the fuel injector rail.
  18. Install the spark plug wires.