Installation Procedure

WARNING: This page is about a different car, the 2003 Oldsmobile Aurora. However, it is still accessible from the selected car via links, so may be relevant.

Lightly grease the inside edge of the rubber plenum duct.

Fig 1: Greasing Inside Edge Of Rubber Plenum Duct
Courtesy of GENERAL MOTORS CORP.
Clean any debris from the cylinder head or intake manifold.
Install the new gaskets to the intake manifold.
Important: Ensure the PCV valve hose is firmly connected to the fitting at the front of the intake manifold, prior to installation.
Place the intake manifold in position by completing the following:
1. 4.1. Position the rear of the intake manifold (1) into the plenum duct (2).
2. 4.2. Position the front of the intake manifold (1) downward onto the cylinders heads.
Fig 2: Positioning Intake Manifold
Courtesy of GENERAL MOTORS CORP.
Loosely install the 10 bolts attaching the intake manifold (1) to the cylinder heads.

Fig 3: Installing Bolts Attaching Intake Manifold To Cylinder Heads
Courtesy of GENERAL MOTORS CORP.

NOTE: Refer to FASTENER NOTICE .
Tighten the intake manifold bolts in sequence (1-10).

Fig 4: Tightening Sequence Of Intake Manifold Bolts
Courtesy of GENERAL MOTORS CORP.

Tighten

Tighten the intake manifold bolts to 10 N.m (89 lb in).
Ensure that the plenum duct is fully attached to the rear of the intake manifold.
Tighten

Tighten the plenum duct clamp (1) to 2.25 N.m (20 lb in).

Fig 5: Attaching Plenum Duct To Rear Of Intake Manifold
Courtesy of GENERAL MOTORS CORP.
Lubricate the intake manifold fuel injector bores with light mineral oil GM P/N 9981704, clean engine oil, or equivalent.
Important: DO NOT force the injectors into position.
Install the entire fuel rail and injector assembly into the intake manifold by pressing the fuel rail and injector simultaneously into the correct position.

Fig 6: Installing Fuel Rail And Injector Assembly Into Intake Manifold
Courtesy of GENERAL MOTORS CORP.
Install the 4 bolts (1) attaching the fuel rail (2) to the intake manifold (3).
Tighten

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

Fig 7: Installing Bolts Attaching Fuel Rail To Intake Manifold
Courtesy of GENERAL MOTORS CORP.
Connect the 8 electrical connectors (1) to the 8 fuel injectors (2).

Fig 8: Connecting Electrical Connectors To Fuel Injectors
Courtesy of GENERAL MOTORS CORP.
Position the surge tank pipe (2) on to the fuel rail studs.
Position the engine coolant heater wire (1) on to the fuel rail studs (if equipped).
Install the 2 pushnuts.

Fig 9: Positioning Surge Tank Pipe And Engine Coolant Heater Wire
Courtesy of GENERAL MOTORS CORP.
Install the fuel rail bracket retaining nut (1) to the rear lift bracket.

Fig 10: Installing Fuel Rail Bracket Retaining Nut To Rear Lift Bracket
Courtesy of GENERAL MOTORS CORP.

Tighten

Tighten the fuel rail bracket retaining nut (1) to 10 N.m (89 lb in).
Install the quick connect fittings to the fuel rail. Refer to FUEL LINE DISCONNECT FITTINGS .
Connect the vacuum tubes (2) to the AIR solenoid.

Fig 11: Connecting Vacuum Tubes
Courtesy of GENERAL MOTORS CORP.
Connect the fuel regulator vacuum tube (1).
Connect the brake booster vacuum hose to the intake manifold.
Connect the PCV fresh air tube (1) to the camshaft cover.

Fig 12: Connecting PCV Fresh Air Tube To The Camshaft Cover
Courtesy of GENERAL MOTORS CORP.
Connect the PCV valve air tube (2) to the camshaft cover.

Fig 13: Connecting PCV Valve Air Tube To Camshaft Cover
Courtesy of GENERAL MOTORS CORP.
Connect the coil module connectors (1) to the coil modules (2) located in the camshaft covers (3).

Fig 14: Connecting Coil Module Connectors To Coil Modules
Courtesy of GENERAL MOTORS CORP.
Turn the ignition switch to the ON position for 2 seconds, then turn to the OFF position for 10 seconds. Again turn to the ON position and check for fuel leaks.
Install the fuel injector sight shield. Refer to FUEL INJECTOR SIGHT SHIELD REPLACEMENT .