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HOMESERVICE MANUALSPONTIAC2006G6 GTP, 2D COUPE, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 30 (ENGINE MECHANICAL)REPAIR INSTRUCTIONSON-VEHICLE REPAIR INSTRUCTIONSINTAKE MANIFOLD REPLACEMENTINSTALLATION PROCEDURE
2006 Pontiac G6 GTP, 2D Coupe, Standard

Installation Procedure

2006 Pontiac G6 GTP, 2D Coupe, StandardSECTION Installation Procedure
WARNING: This page is about a different car, the 2005 Saturn L300. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Removing & Installing Intake Manifold
    GM896462Courtesy of GENERAL MOTORS CORP.
  1. Remove the masking from the intake ports.
  2. Install the manifold gaskets.
  3. Install the manifold spacer.
  4. Install the manifold spacer bolts. Apply LOCTITE® 242 threadlocker, or equivalent, to the bolts.

    Tighten:  Tighten the intake manifold spacer bolt to 20 N.m (15 lb ft).

  5. Install the intake manifold gaskets.
  6. Install the intake manifold.
  7. Install the intake manifold bolts. Apply LOCTITE® 242 threadlocker, or equivalent, to the bolts.

    Tighten:  Tighten the intake manifold bolt to 20 N.m (15 lb ft).

    8. Fig 2: Removing & Installing Fuel Rail Assembly
    GM896453Courtesy of GENERAL MOTORS CORP.
  8. Install the fuel injector electrical harness and connectors.
  9. Install the fuel rail.

    Tighten:  Tighten the fuel rail bolts to 8 N.m (71 lb in).

    10. Fig 3: Removing & Installing Intake Plenum
    GM896435Courtesy of GENERAL MOTORS CORP.
  10. Connect the fuel supply hose.
  11. Connect the fuel return hose.
  12. Install the upper intake plenum.
  13. Install the plenum bolts and EGR manifold bolt.

    Tighten: 

    • Tighten the intake plenum bolts to 8 N.m (71 lb in).
    • Tighten the EGR manifold bolt to 8 N.m (71 lb in).

  14. Install the intake plenum clamp using the J 43914  .
  15. Connect the negative battery cable.

    Tighten:  Tighten the battery terminal bolts to 17 N.m (13 lb ft).

  16. Crank the engine but do not start. Check for fuel leaks.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.