GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2003 🢒 Grand Am 🢒 Engine 🢒 Engine Mechanical - 3.4L 🢒 Lower Intake Manifold Replacement

Removal Procedure

    Object Number: 187076 Size: SH
  1. Remove the upper intake manifold. Refer to Upper Intake Manifold Replacement.
  2. Remove the valve rocker covers. Refer to Valve Rocker Arm Cover Replacement - Left Side and Valve Rocker Arm Cover Replacement - Right Side.

    3. Object Number: 190516 Size: SH
  3. Remove the fuel rail with injectors and position aside. Refer to Fuel Injection Fuel Rail Assembly Replacementin Engine Controls - 3.4L.
  4. Disconnect ECT.
  5. Remove the power steering mounting bolts. Position the pump aside. Refer to Power Steering Pump Replacement in Power Steering Systems.

    6. Object Number: 187060 Size: SH
  6. Remove the inlet cooling pipe from the coolant outlet housing.
  7. Remove the heater by-pass at the coolant pump and the cylinder head.
  8. Remove the radiator hose from thermostat housing.

    9. Object Number: 54281 Size: SH

    Important: Retain the washers in the same orientation on the center bolts.

  9. Remove the lower intake manifold bolts and discard the bolts.
  10. Remove the lower intake manifold.

    11. Object Number: 54392 Size: SH
  11. Loosen the rocker arms.

    12. Object Number: 187046 Size: SH

    Important: Keep the pushrods in order. The pushrods must be installed in the original position.

  12. Remove the pushrods.

    13. Object Number: 61187 Size: SH
  13. Remove the intake gasket.
  14. Inspect the flatness of the inlet flanges.
  15. If replacing intake remove the following components:
    16. • ECT
    • Thermostat housing
    • Thermostat

Installation Procedure

    Important: All gasket-mating surfaces need to be free of oil, and foreign material. Use GM P/N 12346139 (Canadian P/N 10953463) or equivalent to clean surfaces.


    Object Number: 61187 Size: SH
  1. Install the intake manifold gasket.

    2. Object Number: 187046 Size: SH
  2. Install the pushrods.
    3. 2.1. Install the pushrods in their original location.
    2.2. Coat the ends of the pushrods with prelube GM P/N 12345501 or GM P/N 8862586 (Canadian P/N 992704 or Canadian P/N 8862586) or the equivalent.
    2.3. Intake pushrods are 144 mm (5.75 in).
    2.4. Exhaust pushrods are 152.5 mm (6.0 in).
    2.5. Ensure that the pushrods seat in the lifter.

    Notice: Refer to Fastener Notice in the Preface section.

  3. Install the rocker arm bolts.

    4. Tighten
    Tighten the bolts to 19 N·m (14 lb ft).


    Object Number: 843417 Size: SH

    Important: All gasket-mating surfaces need to be free of oil, and foreign material. Use GM P/N 12346139 (Canadian P/N 10953463) or equivalent to clean surfaces.

  4. With gaskets in place apply a small drop 8-10 mm (0.31-0.39 in) of RTV sealer GM P/N 12346141 (Canadian P/N 89022195) or equivalent to the 4 corners of the intake manifold to block joint (1).
  5. Connect the 2 small drops with a bead of RTV sealer that is between 8-10 mm (0.31-0.39 in) wide and 3.0-5.0 mm (0.12-0.20 in) thick (2).
  6. Install the lower intake manifold.

    7. Object Number: 187067 Size: SH

    Important: 

       â€¢ All lower intake manifold bolts need to be cleaned and free of any foreign material, only new bolts are to be used.
       â€¢ Manufacturer recommends the center bolts be fully torqued before the diagonal bolts to assure proper seal ability.
       â€¢ Lower intake manifold bolts in location 6 and 7 should be torqued to specification using a crows foot type tool.

  7. Install NEW lower intake manifold bolts.

    8. Tighten

    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 (1, 2, 3, 4) in sequence to 13 N·m (115 lb in) on the final pass.
    3. Tighten the lower intake manifold bolts (5, 6, 7, 8) in sequence to 25 N·m (18 lb ft) on the final pass.
  8. Install the thermostat housing. Refer to Engine Coolant Thermostat Housing Replacement in Engine Cooling.
  9. Install the radiator hose to the thermostat housing.

    10. Object Number: 187060 Size: SH
  10. Install the heater inlet pipe to the thermostat housing.

    11. Object Number: 862487 Size: SH

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

  11. Install the fuel injector rail assembly.
    12. 11.1. Install the fuel injector O-rings using GM P/N 12345616, (Canadian P/N 993182) or equivalent.
    11.2. Install the injector nozzles into the lower intake manifold injector bores.
    11.3. Press on the injector rail using the palms of both hands until the injectors are fully seated.
  12. Install the fuel injector rail bolts.

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


    Object Number: 187065 Size: SH
  13. Install the fuel feed and return pipe retaining clip.
  14. Install the fuel feed and return pipe retaining clip bolt.

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


    Object Number: 54358 Size: SH
  15. Install the upper intake manifold. Refer to Upper Intake Manifold Replacement.
  16. Install the valve rocker covers. Refer to Valve Rocker Arm Cover Replacement - Left Side.