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Home >> Hummer >> 2004 >> H2 4D Utility Pickup >> Repair and Diagnosis >> External Pages >> Different car >> Section 249 (Engine Mechanical - 3.5L (Unit Repair)) >> Repair Instructions >> Intake Manifold Installation
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Intake Manifold Installation

WARNING: This page is about a different car, the 2002 Oldsmobile Aurora and 2001 Oldsmobile Aurora. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the intake manifold.
    Fig 1: Installing Intake Manifold
    G01815522Courtesy of GENERAL MOTORS CORP.
  2. Connect the throttle body heater hose to the water crossover feed tube (1).
  3. Install the hose clamp.
    Fig 2: Connecting Throttle Body Heater Hose To Water Crossover Feed Tube
    G01815523Courtesy of GENERAL MOTORS CORP.
  4. Loosely install the intake manifold bolts.
    Fig 3: Installing Intake Manifold Bolts
    G01815524Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to in FASTENER NOTICE .
  5. Tighten the intake manifold bolts in sequence (1-8) as shown.

    Tighten 

    Tighten the intake manifold bolts to 10 N.m (89 in lbs).

  6. Inspect the fuel injector O-rings. Ensure the fuel injector O-rings are not missing, mis-aligned or damaged. Replace the O-rings if necessary.
  7. Lubricate the intake manifold fuel injector bores with light mineral oil GM P/N 9981704, clean engine oil, or equivalent.
  8. Install the fuel rail with fuel injectors as an assembly.
    Fig 4: Identifying Intake Manifold Bolts Tightening Sequence
    G01815525Courtesy of GENERAL MOTORS CORP.
  9. Inspect the fuel injector O-rings (2) for misalignment or damage. Replace the O-rings if necessary.
  10. Install the fuel rail (1) and fuel injectors (2) by aligning the fuel injectors with their respective ports and pressing the four fuel rail snap-lock connectors into the intake manifold until they lock in place. DO NOT apply excessive pressure to the fuel rail in place. The need for excessive pressure may be caused by misalignment of a fuel injector and could cause damage to the seal or intake manifold.
    Fig 5: Installing Fuel Rail & Injectors
    G01815526Courtesy of GENERAL MOTORS CORP.

    Important:  The EGR valve outlet pipe incorporates a crush seal connection at the water crossover. The EGR valve outlet pipe must be replaced if disconnected from the water crossover.

  11. Install the NEW EGR outlet pipe with NEW O-ring seal.
  12. Install the EGR outlet pipe to intake manifold bolt.

    Tighten 

    Tighten the EGR outlet pipe to intake manifold bolt to 10 N.m (89 in lbs).

  13. Install the EGR outlet pipe to water crossover bolts.

    Tighten 

    Tighten the EGR outlet pipe to water crossover bolts to 24 N.m (18 ft lbs).

    Fig 6: Installing EGR Outlet Pipe
    G01815527Courtesy of GENERAL MOTORS CORP.
  14. Install the PCV valve and connect both feed tubes (1, 2) to the camshaft covers and intake manifold.
    Fig 7: Installing PCV Valve
    G01815528Courtesy of GENERAL MOTORS CORP.
  15. Connect the fuel pressure regulator vacuum tube (1) to the regulator (2) and the throttle body (3).
    Fig 8: Connecting Fuel Pressure Regulator Vacuum Tube
    G01815529Courtesy of GENERAL MOTORS CORP.
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