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Intake Manifold Installation - Lower

NOTE: When replacing lower intake manifold gasket, a revised intake manifold gasket has been introduced by manufacturer. This new design gasket helps resolve issues related to intake manifold oil/coolant leaks. The gasket requires a revised torque specification and procedure in addition to the use of NEW revised intake manifold bolts. Please review TSB ENGINE OIL OR COOLANT LEAK (INSTALL NEW INTAKE MANIFOLD GASKET) for complete information.
  1. Apply sealer GM P/N United States 12378479, GM P/N Canada 10953472 or the equivalent at the engine block-to-lower intake manifold mating surface.

    Ensure that the bead meets the following conditions:

    • 8.0-10.0 mm (0.31-0.39 in) wide
    • 3.0-5.0 mm (0.12-0.20 in) thick
  2. Install the lower intake manifold.
    Fig 1: Lower Intake Manifold
    G01829092Courtesy of GENERAL MOTORS CORP.
    NOTE: Failure to tighten vertical bolts before the diagonal bolts may cause an oil leak.
  3. Apply sealer GM P/N United States 12345382, GM P/N Canada 10953489 or the equivalent to the lower intake manifold bolt threads.
    NOTE: Refer to FASTENER NOTICE .
  4. Install the lower intake manifold bolts.

    Tighten 

    1. 4.1. Tighten the lower intake manifold bolts in sequence to 7 N.m (62 lb in) on the first pass.
    2. Tighten the lower intake manifold bolts in sequence to 13 N.m (115 lb in) on the final pass.
    Fig 2: Lower Intake Manifold Bolts Tightening Sequence
    G01829093Courtesy of GENERAL MOTORS CORP.
  5. Install the heater inlet pipe.
    6. Fig 3: Heater Inlet Pipe
    G01829094Courtesy of GENERAL MOTORS CORP.
  6. Install the heater inlet pipe nut.

    Tighten 

    Tighten the heater inlet pipe nut to 25 N.m (18 lb ft).

    Important:  Do not press on the fuel pressure regulator valve when installing the fuel injector rail assembly.

  7. Install the fuel injector rail assembly.
    1. Install the fuel injector O-rings using GM P/N United States 12345616, GM P/N Canada 993182 or the equivalent.
    2. Install the injector nozzles into the lower intake manifold injector bores.
      3. Fig 4: Fuel Injector Rail
      G01829095Courtesy of GENERAL MOTORS CORP.
    3. Press on the injector rail using the palms of both hands until the injectors are fully seated.
  8. Install the fuel injector rail bolts.

    Tighten 

    Tighten the fuel injector rail bolts to 10 N.m (89 lb in).

    9. Fig 5: Fuel Feed And Return Pipe Retaining Clip
    G01829096Courtesy of GENERAL MOTORS CORP.
  9. Install the fuel feed and return pipe retaining clip.
  10. Install the fuel feed and return pipe retaining clip bolt.

    Tighten 

    Tighten the fuel feed and return pipe retaining clip bolt to 8 N.m (71 lb in).

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