Notice: Apply the proper amount of the sealant when assembling this
component. Excessive use of the sealant can prohibit the component from sealing
properly. A component that is not sealed properly can leak leading to extensive
engine damage.
- Apply a 4.0 mm (0.157 in) patch of adhesive GM P/N 12346141
or equivalent to the cylinder head side of the lower intake manifold gasket
at each end.
Important: The lower intake manifold gasket must be installed while the adhesive
is still wet to the touch.
- Install the lower intake manifold gasket onto the cylinder head.
Use the gasket locator pins in order to properly seat the lower intake
manifold gasket on the cylinder head.
Notice: Apply the proper amount of the sealant when assembling this component.
Excessive use of the sealant can prohibit the component from sealing properly.
A component that is not sealed properly can leak leading to extensive engine
damage.
Important: The lower 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 P/N 12346141
or equivalent to the front top of the engine block.
- Extend the adhesive bead 13 mm (0.50 in) onto each
lower intake manifold gasket.
- Apply a 5 mm (0.197 in)
bead of adhesive GM P/N 12346141 or equivalent to the rear top
of the engine block.
- Extend the adhesive bead 13 mm (0.50 in) onto each
lower intake manifold gasket.
- Install the lower intake manifold onto the engine block.
- If reusing the fasteners, apply threadlock GM P/N 12345382
or equivalent to the threads of the lower intake manifold bolts.
- Install the lower intake manifold 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 lower
intake manifold bolts.
Tighten
- Tighten the bolts on the first pass in sequence to 3 N·m
(27 lb in).
- Tighten the bolts on the second pass in sequence to 12 N·m
(106 lb in).
- Tighten the bolts on the final pass in sequence to 15 N·m
(11 lb ft).
- Position the power steering
pump mounting bracket.
- Loosely install the power steering pump mounting bracket bolts
and nuts.
- Install the nut for the power steering pump rear bracket at the
front of the engine.
Tighten
Tighten the power steering pump mounting bracket bolts and the power
steering pump rear bracket nuts to 41 N·m (30 lb ft).
- Install the AIR reactor pipe bracket nut to the power steering
pump rear bracket front stud, if equipped.
Tighten
Tighten the AIR reactor pipe bracket nut to 41 N·m (30 lb ft).
- Install the drive belt. Refer to
Drive Belt Replacement
.
- Install the fuel supply and return pipes to the rear of the intake
manifold. Refer to
Fuel Hose/Pipes Replacement - Engine Compartment
in Engine Controls - 4.3L.
Important: In order to install the distributor for the correct engine timing, position
the engine to number one cylinder top dead center.
- Remove the spark plug for number one cylinder.
- Rotate the crankshaft until number one cylinder is in the compression
stroke.
- Align the 2 reference marks on the crankshaft balancer (1) and
(4) with the 2 alignment marks (2) and (3) on the front
cover.
- Install the spark plug. Refer to
Spark Plug Replacement
in Engine Controls - 4.3L.
- Install the distributor. Refer to
Distributor Replacement
in Engine Controls - 4.3L.
- Install the EVAP canister purge solenoid valve. Refer to
Evaporative Emission Canister Purge Solenoid Valve Replacement
in Engine Controls - 4.3L.
- Install the EGR valve
inlet pipe to the intake manifold and the exhaust manifold.
Tighten
- Tighten the EGR valve inlet pipe intake manifold nut to 25 N·m
(18 lb ft).
- Tighten the EGR valve inlet pipe exhaust manifold nut to 30 N·m
(22 lb ft).
- Tighten the EGR valve inlet pipe clamp bolt 25 N·m
(18 lb ft).
- Install the spark plug wire harness retainer on the EGR valve
inlet pipe.
- Install the PCV hose assembly
to the intake manifold and the valve rocker arm cover.
- Install the accelerator
cable and cruise control cable bracket to the throttle body.
Tighten
Tighten the accelerator cable and cruise control bracket nuts to 9 N·m
(80 lb in).
- Install the accelerator
cable bracket to the intake manifold and the throttle body.
Tighten
Tighten the accelerator cable bracket studs and nuts to 12 N·m
(106 lb in).
- Position the engine wiring
harness.
- Install the engine wiring harness clips in the brackets.
- Connect the following electrical connectors:
• | The idle air control (IAC) motor (3) |
• | The throttle position (TP) sensor (2) |
• | The A/C compressor cutoff switch, if equipped (5) |
• | The A/C clutch switch, if equipped (1) |
• | The engine coolant temperature (ECT) sensor (4) |
- Connect the following
electrical connectors:
• | The fuel meter body assembly (1) |
• | The EVAP canister purge solenoid valve (2) |
• | The manifold air pressure (MAP) sensor (3) |
- Connect the following
electrical connectors:
• | The exhaust gas recirculation (EGR) valve (3) |
• | The ignition control module (ICM) (1) |
- Connect the power brake
booster vacuum hose.
- Connect the vacuum hose to the intake manifold, if equipped with
A/C.
- Install the water pump inlet hose to the intake manifold.
- Install the heater hose to the intake manifold. Refer to
Heater Inlet Hose Replacement
and
Heater Outlet Hose Replacement
in Heating, Ventilation
and Air Conditioning.
- Install the radiator inlet hose to the thermostat housing. Refer
to
Radiator Inlet Hose Replacement
in Engine Cooling.
- Install the cruise control cable, if equipped to the bracket and
the throttle shaft. Refer to
Cruise Control Cable Replacement
in Cruise Control.
- Install the accelerator
cable onto the throttle body.
- Wrap the cable in between
the finger of the hook tab and the pulley wall. Make sure that the cable is
fully seated in the pulley groove. The cable must not lie outside of the
hook tab.
- Install the accelerator
cable to the accelerator cable control bracket.
Notice:
• | Handle the MAF sensor carefully. |
• | Do not drop the MAF sensor in order to prevent damage to the MAF
sensor. |
• | Do not damage the screen located on the air inlet
end of the MAF. |
• | Do not touch the sensing elements. |
• | Do not allow solvents and lubricants to come in contact with the
sensing elements. |
• | Use a small amount of a soap based solution in order to aid in
the installation. |
- Install air cleaner outlet
duct to throttle body.
- Install air cleaner outlet duct to MAF sensor.
Tighten
Tighten the hose clamp to 4 N·m (32 lb in).
- Connect the IAT sensor
harness connector.
- Install the air cleaner
outlet duct retaining wingnut.
Tighten
Tighten the wingnut to 2 N·m (18 lb in).
- Connect the breather tube
to the air cleaner outlet duct.
- Fill the cooling system. Refer to
Cooling System Draining and Filling
in Engine Cooling.
- Connect the battery negative cable. Refer to
Battery Negative Cable Disconnection and Connection
in Engine Electrical.