- Apply a 4.0 mm
(0.157 in) patch of adhesive GM U.S. P/N 12346141,
Canada P/N 10953433, or equivalent to the cylinder head side
of the intake manifold gasket at each end.
Important: The intake manifold gasket must be installed while the adhesive is still
wet to the touch.
- Install the intake manifold gasket onto the cylinder head. Use
the gasket locating pins in order to properly seat the gasket.
Important: The intake manifold must be installed and the fasteners tightened while
the adhesive is still wet to the touch.
- Apply a 5 mm (0.197 in) bead of adhesive GM U.S. P/N 12346141,
Canada P/N 10953433, or equivalent to the front top of the engine
block.
- Extend the adhesive bead 13 mm (0.50 in) onto each
intake manifold gasket.
- Apply a 5 mm (0.197 in)
bead of adhesive GM U.S. P/N 12346141, Canada P/N 10953433,
or equivalent to the rear top of the engine block.
- Extend the adhesive bead 13 mm (0.50 in) onto each
intake manifold gasket.
- Install the intake manifold.
- If reusing the old fasteners, apply threadlock GM U.S. P/N 12345382,
Canada P/N 10953489, or equivalent to the threads
of the intake manifold - lower bolts.
- Install the intake manifold - lower bolts.
Notice: Proper lower intake manifold fastener tightening sequence
and torque is critical. Always follow the tightening sequence, and torque
the intake manifold bolts using the 3 step method. Failing to do so may distort
the crankshaft bearing bore alignment and cause damage to the crankshaft bearings.
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.
- Tighten the intake
manifold - lower bolts in sequence shown.
Tighten
- Tighten the intake manifold - lower bolts a first pass to 3 N·m
(27 lb in).
- Tighten the intake manifold - lower bolts a second pass to 12 N·m
(106 lb in).
- Tighten the intake manifold - lower bolts a final pass to 15 N·m
(11 lb ft).
- Slide the P/S pump bracket
rearward.
- Install the bolts and the nut for the P/S pump bracket.
- Install the P/S pump rear bracket front nut.
- Tighten the P/S pump rear bracket nut.
Tighten
Tighten the P/S pump bracket bolts and nuts to 41 N·m (30 lb ft).
- Install the drive belt. Refer to
Drive Belt Replacement
.
- Install the EGR valve
inlet pipe until snug.
- Install the EGR valve inlet pipe bracket bolt.
Tighten
• | Tighten the EGR valve inlet pipe fitting to the exhaust manifold
to 25 N·m (18 lb ft). |
• | Tighten the EGR valve inlet pipe fitting to the intake manifold
to 30 N·m (22 lb ft). |
• | Tighten the EGR valve inlet pipe bracket bolt to 25 N·m
(18 lb ft). |
- Install the spark plug
wire harness retainer to the EGR valve inlet pipe.
- Install the water pump inlet hose.
- Position the water pump inlet hose clamps.
- Install the radiator inlet
hose to the thermostat housing.
- Position the radiator inlet hose clamps.
- Connect the power brake
booster vacuum hose to the vacuum fitting (1).
- Install the PCV valve
hose to the PCV valve cover and the rocker arm cover.
- Position the engine wiring
harness and bracket.
- Install the engine wiring harness bracket stud.
Tighten
Tighten the engine wiring harness rear bracket stud to 25 N·m
(18 lb ft).
- Install the engine wiring harness rear bracket nut at the EVAP
canister purge solenoid valve.
Tighten
Tighten the engine wring harness rear bracket nut to 9 N·m
(80 lb in).
- Install the engine wiring
harness ground nut and ground wire (4) to the rear of the right cylinder head.
Tighten
Tighten the engine wiring harness ground nut to 16 N·m
(12 lb ft).
- Install the engine wiring
harness bracket to the studs.
- Install the engine wiring harness bracket nuts.
Tighten
Tighten the engine wiring harness bracket nuts to 12 N·m
(106 lb in).
- Connect the EVAP canister
harness to the purge solenoid valve.
- Connect the following
electrical connectors:
• | The EVAP canister purge solenoid valve (1) |
- Connect the following
electrical connectors:
• | The control port injector module (3) |
- Install the engine wiring harness clip bolt (4).
Tighten
Tighten the engine wiring harness clip bolt to 9 N·m (80 lb in).
- Position the bracket and
cables.
- Install the accelerator control cable bracket with the cables
attached, to the throttle body.
- Install the accelerator control cable bracket nuts.
Tighten
Tighten the accelerator control cable bracket nuts to 9 N·m
(80 lb in).
- Connect the following
electrical connectors:
• | The A/C compressor clutch (1), if equipped |
• | The A/C pressure switch (4), if equipped |
- Install the engine wiring harness clip (3) to the accelerator
control cable bracket.
- Install the accelerator
cable to the accelerator control cable bracket.
- Install the accelerator
cable to the throttle body lever.
- Install the cruise control
cable to the accelerator control cable bracket, if equipped.
- Connect the cruise control cable to the throttle lever, if equipped.
- Position the heater inlet
and outlet hoses.
- Install the heater inlet hose to the water pump.
- Install the heater outlet hose clip bolt.
Tighten
Tighten the heater outlet hose clip bolt to 25 N·m (18 lb ft).
- Position the heater inlet hose clamp.
- Install the heater outlet
hose to the intake manifold.
- Position the heater outlet hose clamp.
- Connect the EVAP canister
harness to the purge solenoid valve.
- Install the fuel pipes/hoses. Refer to
Fuel Hose/Pipes Replacement - Engine Compartment
in Engine Controls
- 4.3L.
- Install the distributor. Refer to
Distributor Replacement
in Engine Controls - 4.3L.
- Fill the cooling system. Refer to
Cooling System Draining and Filling
in Engine Cooling.