[eleveniron]

Hi Jim,

Once you remove the one bolt from the flange of the metal coolant line it should come out without too much force. It's just stuck on the o-ring a bit. Wiggle it around as you pull it straight up.

You could lift ot the lower manifold with the injector rail still in, however i would recommend you take it off first. The injectors are also stuck on the o-rings and it doesn't hurt to use some light oil like WD-40 or LPS. Spray each injector at the base wheer it is stuck into the manifold and the oil should free up the orings. Don't pry too hard or you could bend the rail. Just work on each injector a little at a time. The reason I say you will have to remove it anyway is because when it comes to handling and cleaning the manifold after removal, you don't want to risk damaging or contaminating the holes on the injectors.

Here are the instructions for installing the lower manifild bolts. Very important to tighten the 4 center bolts before the 4 diagonal bolts on the ends. It doesn't say so, but you should use a typical criss-cross pattern when torqing the bolts.

Also, in addition to the instructions below, pay attention to this note which is a revison to the original install procedure regarding application of the sealant...


1. Install the intake manifold gaskets.

2. Apply small drops (8-10 mm [0.31-0.39 in]) of RTV sealer, GM P/N 12346286 (in Canada, use GM P/N 10953476) or the equivalent to the four corners of the intake manifold to block joint (1).

3. Connect the 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).

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Install the lower intake manifold.
Apply sealant GM P/N 12345739 at engine block to manifold mating surface. Bead should be 2.0-3.0 mm (0.08-0.12 inch) wide and 3.0-5.0 mm (0.12-0.20 in) thick.
CAUTION: Failure to tighten vertical bolts before the diagonal bolts may cause an oil leak.

Install the lower intake manifold retaining bolts.
Apply sealant GM P/N 12345382 to the threads of the bolts.
Tighten the vertical bolts to 13 Nm (115 inch lbs.) .
Tighten the diagonal bolts to 13 Nm (115 inch lbs.) .

Install the heater inlet pipe assembly.

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

Install the fuel injector rail assembly.
Lightly lubricate the fuel injector O-rings using GM P/N 1051885.
Install the injectors of the fuel rail assembly into the bores of the manifold.
Carefully press on the injector rail with the palms of both hands until the injectors are fully seated.
Install the fuel injector rail bolts.
Tighten the bolts to 10 Nm (89 inch lbs.) .