Avalanche, Sierra, Silverado, C&K Series, 1999-2005

Intake Manifold 1

Print

Removal & Installation



4.3L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air intake duct
     
    Wiring harness connectors and brackets from the manifold
     
    Throttle linkage and bracket from the upper manifold
     
    Cruise control cable, if equipped
     
    Fuel lines at the rear of the lower intake manifold
     
    Brake booster vacuum hose from the upper intake manifold
     
    Ignition coil and bracket
     
    Purge solenoid and bracket
     
    Studs and intake manifold attaching bolts, mark for reassembly
     
    Upper intake manifold
     
    Distributor housing and rotor, mark for reassembly
     
    Upper radiator hose from the thermostat housing
     
    Heater hoses and the bypass hose from the lower intake manifold
     
    Exhaust Gas Recirculation (EGR) valve
     
    Transmission dipstick tube, if equipped
     
    Positive Crankcase Ventilation (PCV) valve and hoses
     
    Air conditioning compressor and bracket. Without disconnecting, position aside
     
    Alternator bracket and bolt next to the thermostat housing, if needed
     
    Lower intake manifold mounting bolts and the lower manifold
     

  6.  

To install:

  1. Clean all gasket mating surfaces thoroughly.
  2.  
  3. Position the new gaskets on the cylinder heads with the port blocking plates at the rear and the words THIS SIDE UP facing up.
  4.  
  5. Apply a 3 / 16 inch (5mm) bead of RTV to the front and rear sealing surfaces on the engine block. Extend the bead 1 / 2 inch (13mm) up each cylinder head to retain the gasket.
  6.  
  7. Carefully position the lower intake manifold onto the engine.
  8.  
  9. Apply GM 1052080 or equivalent sealer to the lower intake manifold bolts
  10.  
  11. Torque the bolts using 3 steps in the sequence shown:
    1. Step 1: 24 inch lbs. (3 Nm).
    2.  
    3. Step 2: 108 inch lbs. (12 Nm).
    4.  
    5. Step 3: 11 ft. lbs. (15 Nm).

      Click image to see an enlarged view

      Fig. Lower intake manifold bolt tightening sequence-4.3L engines

    6.  

  12.  
  13. Install or connect the following:

    Alternator bracket and bolts near the thermostat housing, if removed
     
    Air conditioning compressor
     
    PCV valve and hose
     
    Transmission dipstick tube, if equipped
     
    EGR valve
     
    Upper radiator and bypass hose to the thermostat housing
     
    Distributor.
     

  14.  
  15. Position the upper intake manifold gasket on the lower manifold.
    WARNING
    Be careful not to pinch the injector tubes between the upper and lower manifolds.



    Upper intake manifold. Torque the bolts and studs to 88 inch lbs. (10 Nm).
     
    Purge control bracket and valve
     
    Ignition coil
     
    Brake booster vacuum
     
    Fuel lines
     
    Accelerator cable
     
    Cruise control cable, if equipped
     
    Wiring harness brackets and connections
     
    Air intake duct
     
    Negative battery cable
     

  16.  
  17. Refill and bleed the cooling system.
  18.  
  19. Pressurize the fuel system and check for leaks.
  20.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air intake duct
     
    Wiring harness connectors and brackets from the manifold
     
    Throttle linkage and bracket from the upper manifold
     
    Cruise control cable, if equipped
     
    Fuel lines at the rear of the lower intake manifold
     
    Brake booster vacuum hose from the upper intake manifold
     
    Ignition coil and bracket
     
    Purge solenoid and bracket
     
    Studs and intake manifold attaching bolts, mark for reassembly
     
    Upper intake manifold
     
    Distributor housing and rotor, mark for reassembly
     
    Upper radiator hose from the thermostat housing
     
    Heater hoses and the bypass hose from the lower intake manifold
     
    Exhaust Gas Recirculation (EGR) valve
     
    Transmission dipstick tube, if equipped
     
    Positive Crankcase Ventilation (PCV) valve and hoses
     
    Air conditioning compressor and bracket. Without disconnecting position out of the way
     
    Alternator bracket and bolt next to the thermostat housing. If needed
     
    Lower intake manifold mounting bolts and the lower manifold
     

  6.  

To install:

  1. Clean all gasket mating surfaces thoroughly.
  2.  
  3. Position the new gaskets on the cylinder heads with the port blocking plates at the rear and the words THIS SIDE UP facing up.
  4.  
  5. Apply a 3 / 16 inch (5mm) bead of RTV to the front and rear sealing surfaces on the engine block. Extend the bead 1 / 2 inch (13mm) up each cylinder head to retain the gasket.
  6.  
  7. Carefully position the lower intake manifold onto the engine.
  8.  
  9. Apply GM 1052080 or equivalent sealer to the lower intake manifold bolts
  10.  
  11. Torque the bolts using 3 steps in the sequence shown,
    1. Step 1: Torque the bolt to 24 inch lbs. (3 Nm)
    2.  
    3. Step 2: Then torque to 108 inch lbs. (12 Nm)
    4.  
    5. Step 3: And finally torque to 11 ft. lbs. (15 Nm)

      Click image to see an enlarged view

      Fig. Lower intake manifold bolt tightening sequence-4.3L engines

    6.  

  12.  
  13. Install or connect the following:

    Alternator bracket and bolts near the thermostat housing, if removed
     
    Air conditioning compressor
     
    PCV valve and hose
     
    Transmission dipstick tube, if equipped
     
    EGR valve
     
    Upper radiator and bypass hose to the thermostat housing.
     
    Distributor.
     

  14.  
  15. Position the upper intake manifold gasket on the lower manifold.
    WARNING
    Be careful not to pinch the injector tubes between the upper and lower manifolds.



    Upper intake manifold. Torque the bolts and studs to 88 inch lbs. (10 Nm)
     
    Purge control bracket and valve
     
    Ignition coil
     
    Brake booster vacuum
     
    Fuel lines
     
    Accelerator cable
     
    Cruise control cable, if equipped
     
    Wiring harness brackets and connections
     
    Air intake duct
     
    Negative battery cable
     

  16.  
  17. Refill and bleed the cooling system.
  18.  
  19. Pressurize the fuel system and check for leaks.
  20.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air intake duct
     
    Wiring harness connectors and brackets from the manifold
     
    Throttle linkage and bracket from the upper manifold
     
    Cruise control cable, if equipped
     
    Fuel lines at the rear of the lower intake manifold
     
    Brake booster vacuum hose from the upper intake manifold
     
    Ignition coil and bracket
     
    Purge solenoid and bracket
     
    Studs and intake manifold attaching bolts, mark for reassembly
     
    Upper intake manifold
     
    Distributor housing and rotor, mark for reassembly
     
    Upper radiator hose from the thermostat housing
     
    Heater hoses and the bypass hose from the lower intake manifold
     
    Exhaust Gas Recirculation (EGR) valve
     
    Transmission dipstick tube, if equipped
     
    Positive Crankcase Ventilation (PCV) valve and hoses
     
    Air conditioning compressor and bracket. Without disconnecting position out of the way
     
    Alternator bracket and bolt next to the thermostat housing. If needed
     
    Lower intake manifold mounting bolts and the lower manifold
     

  6.  

To install:

  1. Clean all gasket mating surfaces thoroughly.
  2.  
  3. Position the new gaskets on the cylinder heads with the port blocking plates at the rear and the words THIS SIDE UP facing up.
  4.  
  5. Apply a 3 / 16 inch (5mm) bead of RTV to the front and rear sealing surfaces on the engine block. Extend the bead 1 / 2 inch (13mm) up each cylinder head to retain the gasket.
  6.  
  7. Carefully position the lower intake manifold onto the engine.
  8.  
  9. Apply GM 1052080 or equivalent sealer to the lower intake manifold bolts
  10.  
  11. Torque the bolts using 3 steps in the sequence shown,
    1. Step 1: Torque the bolt to 24 inch lbs. (3 Nm)
    2.  
    3. Step 2: Then torque to 108 inch lbs. (12 Nm)
    4.  
    5. Step 3: And finally torque to 11 ft. lbs. (15 Nm)

      Click image to see an enlarged view

      Fig. Lower intake manifold bolt tightening sequence-4.3L engines

    6.  

  12.  
  13. Install or connect the following:

    Alternator bracket and bolts near the thermostat housing, if removed
     
    Air conditioning compressor
     
    PCV valve and hose
     
    Transmission dipstick tube, if equipped
     
    EGR valve
     
    Upper radiator and bypass hose to the thermostat housing.
     
    Distributor.
     

  14.  
  15. Position the upper intake manifold gasket on the lower manifold.
    WARNING
    Be careful not to pinch the injector tubes between the upper and lower manifolds.



    Upper intake manifold. Torque the bolts and studs to 88 inch lbs. (10 Nm)
     
    Purge control bracket and valve
     
    Ignition coil
     
    Brake booster vacuum
     
    Fuel lines
     
    Accelerator cable
     
    Cruise control cable, if equipped
     
    Wiring harness brackets and connections
     
    Air intake duct
     
    Negative battery cable
     

  16.  
  17. Refill and bleed the cooling system.
  18.  
  19. Pressurize the fuel system and check for leaks.
  20.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air intake duct
     
    Wiring harness connectors and brackets from the manifold
     
    Throttle linkage and bracket from the upper manifold
     
    Cruise control cable, if equipped
     
    Fuel lines at the rear of the lower intake manifold
     
    Brake booster vacuum hose from the upper intake manifold
     
    Ignition coil and bracket
     
    Purge solenoid and bracket
     
    Studs and intake manifold attaching bolts, mark for reassembly
     
    Upper intake manifold
     
    Distributor housing and rotor, mark for reassembly
     
    Upper radiator hose from the thermostat housing
     
    Heater hoses and the bypass hose from the lower intake manifold
     
    Exhaust Gas Recirculation (EGR) valve
     
    Transmission dipstick tube, if equipped
     
    Positive Crankcase Ventilation (PCV) valve and hoses
     
    Air conditioning compressor and bracket. Without disconnecting, position aside
     
    Alternator bracket and bolt next to the thermostat housing, if needed
     
    Lower intake manifold mounting bolts and the lower manifold
     

  6.  

To install:

  1. Clean all gasket mating surfaces thoroughly.
  2.  
  3. Position the new gaskets on the cylinder heads with the port blocking plates at the rear and the words THIS SIDE UP facing up.
  4.  
  5. Apply a 3 / 16 inch (5mm) bead of RTV to the front and rear sealing surfaces on the engine block. Extend the bead 1 / 2 inch (13mm) up each cylinder head to retain the gasket.
  6.  
  7. Carefully position the lower intake manifold onto the engine.
  8.  
  9. Apply GM 1052080 or equivalent sealer to the lower intake manifold bolts
  10.  
  11. Torque the bolts using 3 steps in the sequence shown:
    1. Step 1: 27 inch lbs. (3 Nm).
    2.  
    3. Step 2: 106 inch lbs. (12 Nm).
    4.  
    5. Step 3: 11 ft. lbs. (15 Nm).

      Click image to see an enlarged view

      Fig. Lower intake manifold bolt tightening sequence-4.3L engines

    6.  

  12.  
  13. Install or connect the following:

    Alternator bracket and bolts near the thermostat housing, if removed
     
    Air conditioning compressor
     
    PCV valve and hose
     
    Transmission dipstick tube, if equipped
     
    EGR valve
     
    Upper radiator and bypass hose to the thermostat housing
     
    Distributor.
     

  14.  
  15. Position the upper intake manifold gasket on the lower manifold.
    WARNING
    Be careful not to pinch the injector tubes between the upper and lower manifolds.



    Upper intake manifold. Torque the bolts and studs to 88 inch lbs. (10 Nm).
     
    Purge control bracket and valve
     
    Ignition coil
     
    Brake booster vacuum
     
    Fuel lines
     
    Accelerator cable
     
    Cruise control cable, if equipped
     
    Wiring harness brackets and connections
     
    Air intake duct
     
    Negative battery cable
     

  16.  
  17. Refill and bleed the cooling system.
  18.  
  19. Pressurize the fuel system and check for leaks.
  20.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air intake duct
     
    Wiring harness connectors and brackets from the manifold
     
    Throttle linkage and bracket from the upper manifold
     
    Cruise control cable, if equipped
     
    Fuel lines at the rear of the lower intake manifold
     
    Brake booster vacuum hose from the upper intake manifold
     
    Ignition coil and bracket
     
    Purge solenoid and bracket
     
    Studs and intake manifold attaching bolts, mark for reassembly
     
    Upper intake manifold
     
    Distributor housing and rotor, mark for reassembly
     
    Upper radiator hose from the thermostat housing
     
    Heater hoses and the bypass hose from the lower intake manifold
     
    Exhaust Gas Recirculation (EGR) valve
     
    Transmission dipstick tube, if equipped
     
    Positive Crankcase Ventilation (PCV) valve and hoses
     
    Air conditioning compressor and bracket. Without disconnecting, position aside
     
    Alternator bracket and bolt next to the thermostat housing, if needed
     
    Lower intake manifold mounting bolts and the lower manifold
     

  6.  

To install:

  1. Clean all gasket mating surfaces thoroughly.
  2.  
  3. Position the new gaskets on the cylinder heads with the port blocking plates at the rear and the words THIS SIDE UP facing up.
  4.  
  5. Apply a 3 / 16 inch (5mm) bead of RTV to the front and rear sealing surfaces on the engine block. Extend the bead 1 / 2 inch (13mm) up each cylinder head to retain the gasket.
  6.  
  7. Carefully position the lower intake manifold onto the engine.
  8.  
  9. Apply GM 1052080 or equivalent sealer to the lower intake manifold bolts
  10.  
  11. Torque the bolts using 3 steps in the sequence shown:
    1. Step 1: 27 inch lbs. (3 Nm).
    2.  
    3. Step 2: 106 inch lbs. (12 Nm).
    4.  
    5. Step 3: 11 ft. lbs. (15 Nm).

      Click image to see an enlarged view

      Fig. Lower intake manifold bolt tightening sequence-4.3L engines

    6.  

  12.  
  13. Install or connect the following:

    Alternator bracket and bolts near the thermostat housing, if removed
     
    Air conditioning compressor
     
    PCV valve and hose
     
    Transmission dipstick tube, if equipped
     
    EGR valve
     
    Upper radiator and bypass hose to the thermostat housing
     
    Distributor.
     

  14.  
  15. Position the upper intake manifold gasket on the lower manifold.
    WARNING
    Be careful not to pinch the injector tubes between the upper and lower manifolds.



    Upper intake manifold. Torque the bolts and studs to 88 inch lbs. (10 Nm).
     
    Purge control bracket and valve
     
    Ignition coil
     
    Brake booster vacuum
     
    Fuel lines
     
    Accelerator cable
     
    Cruise control cable, if equipped
     
    Wiring harness brackets and connections
     
    Air intake duct
     
    Negative battery cable
     

  16.  
  17. Refill and bleed the cooling system.
  18.  
  19. Pressurize the fuel system and check for leaks.
  20.  

4.8L, 5.3L & 6.0L Engines

NOTE
The intake manifold, throttle body, fuel injection rail, and fuel injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.



Click image to see an enlarged view

Fig. EVAP solenoid removal-4.8L, 5.3L and 6.0L engines

  1. Remove or disconnect the following:

    Positive Crankcase Ventilation (PCV) hose and valve
     
    Manifold Absolute Pressure (MAP) sensor, if required
     
    Engine coolant air bleed clamp and hose from the throttle body
     
    Knock sensor connector, if required.
     
    Accelerator control cable bracket and bolts, if required
     
    Fuel rail with injectors
     
    EVAP solenoid, bolt, and isolator
     
    Intake manifold bolts
     
    Intake manifold with gaskets
     
    Intake manifold-to-cylinder head gaskets from the manifold. Discard the intake manifold gaskets.
     
    Throttle body and gasket

    Click image to see an enlarged view

    Fig. Throttle body removal-4.8L, 5.3L and 6.0L engines

     

  2.  
  3. Clean the intake manifold in solvent.
  4.  
  5. Dry the intake manifold with compressed air.
  6.  
  7. Inspect the throttle body and wire harness studs and stud inserts for looseness or damaged threads.
  8.  
  9. Inspect the fuel rail bolt inserts for looseness or damaged threads.
  10.  
  11. Inspect the intake manifold vacuum passages for debris or restrictions.
  12.  
  13. Inspect for damaged or broken vacuum fittings, damaged MAP sensor mounting bore, or broken MAP sensor retaining tabs.
  14.  
  15. Inspect the composite intake manifold assembly for cracks or other damage.
  16.  
  17. Inspect the areas between the intake runners. Inspect all the gasket sealing surfaces for damage.
  18.  
  19. Inspect the fuel injector bores for excessive scoring or damage. Inspect the intake manifold cylinder head deck for warpage.
  20.  
  21. Locate a straight edge across the intake manifold cylinder head deck surface. Position the straight edge across a minimum of two runner port openings.
  22.  
  23. Insert a feeler gauge between the intake manifold and the straight edge. A intake manifold with warpage in excess of 0.118 in. (3mm) over a 7.87 in. (200mm) area is warped and should be replaced.
  24.  

To install:

  1. Install or connect the following:

    MAP sensor
     
    EVAP solenoid, bolt, and isolator. Tighten the bolt to 89 inch lbs. (10 Nm).
     
    NEW intake manifold-to-cylinder head gaskets
     
    Intake manifold
     

  2.  
  3. Apply a 0.20 in. (5mm) band of threadlock GM P/N 12345382 or equivalent to the threads of the intake manifold bolts.

    Click image to see an enlarged view

    Fig. Lower intake manifold bolt tightening sequence-4.8L, 5.3L and 6.0L engines



    Intake manifold bolts. Tighten intake manifold bolts first pass in sequence to 44 inch lbs. (5 Nm). Tighten intake manifold bolts final pass in sequence to 89 inch lbs. (10 Nm).
     
    PCV valve and hose
     
    Coolant air bleed hose and clamp onto the throttle body
     
    Accelerator control cable bracket and bolts. Tighten the bolts to 89 inch lbs. (10 Nm).
     

  4.  


NOTE
The intake manifold, throttle body, fuel injection rail, and fuel injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.

  1. Remove or disconnect the following:

    Positive Crankcase Ventilation (PCV) hose and valve
     
    Manifold Absolute Pressure (MAP) sensor, if required
     
    Engine coolant air bleed clamp and hose from the throttle body
     
    Knock sensor connector, if required.
     
    Accelerator control cable bracket and bolts, if required
     
    Fuel rail with injectors

    Click image to see an enlarged view

    Fig. EVAP solenoid removal-4.8L, 5.3L and 6.0L engines

     
    EVAP solenoid, bolt, and isolator
     
    Intake manifold bolts
     
    Intake manifold with gaskets
     
    Intake manifold-to-cylinder head gaskets from the manifold. Discard the intake manifold gaskets.

    Click image to see an enlarged view

    Fig. Throttle body removal-4.8L, 5.3L and 6.0L engines

     
    Throttle body and gasket
     

  2.  
  3. Clean the intake manifold in solvent.
  4.  
  5. Dry the intake manifold with compressed air.
  6.  
  7. Inspect the throttle body and wire harness studs and stud inserts for looseness or damaged threads.
  8.  
  9. Inspect the fuel rail bolt inserts for looseness or damaged threads.
  10.  
  11. Inspect the intake manifold vacuum passages for debris or restrictions.
  12.  
  13. Inspect for damaged or broken vacuum fittings, damaged MAP sensor mounting bore, or broken MAP sensor retaining tabs.
  14.  
  15. Inspect the composite intake manifold assembly for cracks or other damage.
  16.  
  17. Inspect the areas between the intake runners. Inspect all the gasket sealing surfaces for damage.
  18.  
  19. Inspect the fuel injector bores for excessive scoring or damage. Inspect the intake manifold cylinder head deck for warpage.
  20.  
  21. Locate a straight edge across the intake manifold cylinder head deck surface. Position the straight edge across a minimum of two runner port openings.
  22.  
  23. Insert a feeler gauge between the intake manifold and the straight edge. A intake manifold with warpage in excess of 0.118 in. (3mm) over a 7.87 in. (200mm) area is warped and should be replaced.
  24.  

To install:

  1. Install or connect the following:

    MAP sensor
     
    EVAP solenoid, bolt, and isolator. Tighten the bolt to 89 inch lbs. (10 Nm).
     
    NEW intake manifold-to-cylinder head gaskets
     
    Intake manifold
     

  2.  
  3. Apply a 0.20 in. (5mm) band of threadlock GM P/N 12345382 or equivalent to the threads of the intake manifold bolts.

    Intake manifold bolts. Tighten intake manifold bolts first pass in sequence to 44 inch lbs. (5 Nm). Tighten intake manifold bolts final pass in sequence to 89 inch lbs. (10 Nm).

    Click image to see an enlarged view

    Fig. Lower intake manifold bolt tightening sequence-4.8L, 5.3L and 6.0L engines

     
    PCV valve and hose
     
    Coolant air bleed hose and clamp onto the throttle body
     
    Accelerator control cable bracket and bolts. Tighten the bolts to 89 inch lbs. (10 Nm).
     

  4.  


NOTE
The intake manifold, throttle body, fuel injection rail, and fuel injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.

  1. Partially drain the engine coolant.
  2.  
  3. Remove or disconnect the following:

    Air cleaner outlet duct
     
    Engine sight shield
     
    Throttle actuator motor electrical connector
     
    Coolant air bleed hose from the throttle body
     
    Throttle body
     
    Fuel rail with injectors
     
    Manifold Absolute Pressure (MAP) sensor, if required
     
    Knock sensor connector
     
    Vacuum brake booster hose from the rear of the intake manifold
     
    Positive Crankcase Ventilation (PCV) hose and valve
     
    EVAP solenoid, bolt, and isolator

    Click image to see an enlarged view

    Fig. EVAP solenoid removal-4.8L, 5.3L and 6.0L engines

     
    Intake manifold bolts
     
    Intake manifold with gaskets
     
    Intake manifold-to-cylinder head gaskets from the manifold. Discard the intake manifold gaskets.
     
    Throttle body and gasket
     

  4.  
  5. Clean the intake manifold in solvent.
  6.  
  7. Dry the intake manifold with compressed air.
  8.  
  9. Inspect all components for damage, and replace the necessary parts.
  10.  
  11. Locate a straight edge across the intake manifold cylinder head deck surface. Position the straight edge across a minimum of two runner port openings.
  12.  
  13. Insert a feeler gauge between the intake manifold and the straight edge. An intake manifold with warpage in excess of 0.118 in. (3mm) over a 7.87 in. (200mm) area is warped and should be replaced.
  14.  

To install:

  1. Install or connect the following:

    MAP sensor
     
    EVAP solenoid, bolt, and isolator. Tighten the bolt to 89 inch lbs. (10 Nm).
     
    NEW intake manifold-to-cylinder head gaskets
     
    Intake manifold. Apply a 0.20 in. (5mm) band of threadlock GM P/N 12345382 or equivalent to the threads of the intake manifold bolts.
     
    Intake manifold bolts. Tighten intake manifold bolts, in sequence, to 44 inch lbs. (5 Nm). Then, tighten the bolts, in sequence, to 89 inch lbs. (10 Nm).

    Click image to see an enlarged view

    Fig. Lower intake manifold bolt tightening sequence-4.8L, 5.3L and 6.0L engines

     
    Vacuum brake booster hose from the rear of the intake manifold
     
    Knock sensor connector
     
    Manifold Absolute Pressure (MAP) sensor, if required
     
    Air cleaner outlet duct
     
    Fuel rail with injectors
     
    Throttle body
     
    Coolant air bleed hose to the throttle body
     
    Throttle actuator motor electrical connector
     
    Engine sight shield
     

  2.  


NOTE
The intake manifold, throttle body, fuel injection rail, and fuel injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.

  1. Remove or disconnect the following:

    PCV hose and valve
     
    MAP sensor, if required
     
    Engine coolant air bleed clamp and hose from the throttle body
     
    Accelerator control cable bracket and bolts, if required

    Click image to see an enlarged view

    Fig. EVAP solenoid removal-4.8L, 5.3L, 6.0L

     
    EVAP solenoid, bolt, and isolator
     
    Intake manifold bolts
     
    Intake manifold with gaskets
     
    Intake manifold-to-cylinder head gaskets from the manifold. Discard the intake manifold gaskets.
     
    Fuel rail with injectors

    Click image to see an enlarged view

    Fig. Throttle body removal-4.8L, 5.3L, 6.0L

     
    Throttle body and gasket
     

  2.  
  3. Clean the intake manifold in solvent.
  4.  
  5. Dry the intake manifold with compressed air.
  6.  
  7. Inspect the throttle body studs and stud inserts for looseness or damaged threads.
  8.  
  9. Inspect the wire harness stud and stud insert for looseness or damaged threads.
  10.  
  11. Inspect the fuel rail bolt inserts for looseness or damaged threads.
  12.  
  13. Inspect the intake manifold vacuum passages for debris or restrictions.
  14.  
  15. Inspect for damaged or broken vacuum fittings, damaged MAP sensor mounting bore, or broken MAP sensor retaining tabs.
  16.  
  17. Inspect the composite intake manifold assembly for cracks or other damage.
  18.  
  19. Inspect the areas between the intake runners. Inspect all the gasket sealing surfaces for damage.
  20.  
  21. Inspect the fuel injector bores for excessive scoring or damage. Inspect the intake manifold cylinder head deck for warpage.
  22.  
  23. Locate a straight edge across the intake manifold cylinder head deck surface. Position the straight edge across a minimum of two runner port openings.
  24.  
  25. Insert a feeler gauge between the intake manifold and the straight edge. A intake manifold with warpage in excess of 3 mm (0.118 in) over a 200 mm (7.87 in) area is warped and should be replaced.
  26.  

To install:


NOTE
Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  1. Install or connect the following:

    MAP sensor
     
    EVAP solenoid, bolt, and isolator. Tighten the EVAP solenoid bolt to 10 Nm (89 inch lbs.).
     
    NEW intake manifold-to-cylinder head gaskets
     
    Intake manifold. Apply a 5 mm (0.20 in) band of threadlock GM P/N 12345382 or equivalent to the threads of the intake manifold bolts.
     
    Intake manifold bolts. Tighten intake manifold bolts first pass in sequence to 5 Nm (44 inch lbs.). Tighten intake manifold bolts final pass in sequence to 10 Nm (89 inch lbs.).

    Click image to see an enlarged view

    Fig. Lower intake manifold bolt tightening sequence-4.8L, 5.3L and 6.0L engines

     
    PCV valve and hose. Install the engine coolant air bleed hose and clamp onto the throttle body.
     
    Accelerator control cable bracket and bolts, if applicable. Tighten the accelerator control cable bracket bolts to 10 Nm (89 inch lbs.).
     

  2.  


NOTE
The intake manifold, throttle body, fuel injection rail, and fuel injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.

  1. Remove or disconnect the following:

    PCV hose and valve
     
    MAP sensor, if required
     
    Engine coolant air bleed clamp and hose from the throttle body
     
    Accelerator control cable bracket and bolts, if required

    Click image to see an enlarged view

    Fig. EVAP solenoid removal-4.8L, 5.3L, 6.0L

     
    EVAP solenoid, bolt, and isolator
     
    Intake manifold bolts
     
    Intake manifold with gaskets
     
    Intake manifold-to-cylinder head gaskets from the manifold. Discard the intake manifold gaskets.
     
    Fuel rail with injectors

    Click image to see an enlarged view

    Fig. Throttle body removal-4.8L, 5.3L, 6.0L

     
    Throttle body and gasket
     

  2.  
  3. Clean the intake manifold in solvent.
  4.  
  5. Dry the intake manifold with compressed air.
  6.  
  7. Inspect the throttle body studs and stud inserts for looseness or damaged threads.
  8.  
  9. Inspect the wire harness stud and stud insert for looseness or damaged threads.
  10.  
  11. Inspect the fuel rail bolt inserts for looseness or damaged threads.
  12.  
  13. Inspect the intake manifold vacuum passages for debris or restrictions.
  14.  
  15. Inspect for damaged or broken vacuum fittings, damaged MAP sensor mounting bore, or broken MAP sensor retaining tabs.
  16.  
  17. Inspect the composite intake manifold assembly for cracks or other damage.
  18.  
  19. Inspect the areas between the intake runners. Inspect all the gasket sealing surfaces for damage.
  20.  
  21. Inspect the fuel injector bores for excessive scoring or damage. Inspect the intake manifold cylinder head deck for warpage.
  22.  
  23. Locate a straight edge across the intake manifold cylinder head deck surface. Position the straight edge across a minimum of two runner port openings.
  24.  
  25. Insert a feeler gauge between the intake manifold and the straight edge. A intake manifold with warpage in excess of 3 mm (0.118 in) over a 200 mm (7.87 in) area is warped and should be replaced.
  26.  

To install:


NOTE
Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  1. Install or connect the following:

    MAP sensor
     
    EVAP solenoid, bolt, and isolator. Tighten the EVAP solenoid bolt to 10 Nm (89 inch lbs.).
     
    NEW intake manifold-to-cylinder head gaskets
     
    Intake manifold. Apply a 5 mm (0.20 in) band of threadlock GM P/N 12345382 or equivalent to the threads of the intake manifold bolts.
     
    Intake manifold bolts. Tighten intake manifold bolts first pass in sequence to 5 Nm (44 inch lbs.). Tighten intake manifold bolts final pass in sequence to 10 Nm (89 inch lbs.).

    Click image to see an enlarged view

    Fig. Lower intake manifold bolt tightening sequence-4.8L, 5.3L and 6.0L engines

     
    PCV valve and hose. Install the engine coolant air bleed hose and clamp onto the throttle body.
     
    Accelerator control cable bracket and bolts, if applicable. Tighten the accelerator control cable bracket bolts to 10 Nm (89 inch lbs.).
     

  2.  


NOTE
The intake manifold, throttle body, fuel injection rail, and fuel injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.

  1. Remove or disconnect the following:

    Alternator
     
    Positive Crankcase Ventilation (PCV) hose and valve
     
    Manifold Absolute Pressure (MAP) sensor, if required
     
    Engine coolant air bleed clamp and hose from the throttle body
     
    Knock sensor connector, if required.
     
    Accelerator control cable bracket and bolts, if required
     
    Fuel rail with injectors, if required
     
    EVAP solenoid, bolt, and isolator
     
    Any additional engine harness attachment points and set aside
     
    Intake manifold bolts
     
    Intake manifold with gaskets
     
    Intake manifold-to-cylinder head gaskets from the manifold. Discard the intake manifold gaskets.

    Click image to see an enlarged view

    Fig. Always use new gaskets-4.8L, 5.3L and 6.0L engines

     

  2.  
  3. Clean the intake manifold in solvent.
  4.  
  5. Dry the intake manifold with compressed air.
  6.  
  7. Inspect the intake manifold vacuum passages for debris or restrictions.
  8.  
  9. Inspect for damaged or broken vacuum fittings, damaged MAP sensor mounting bore, or broken MAP sensor retaining tabs.
  10.  
  11. Inspect the composite intake manifold assembly for cracks or other damage.
  12.  
  13. Inspect the areas between the intake runners. Inspect all the gasket sealing surfaces for damage.
  14.  
  15. Inspect the fuel injector bores for excessive scoring or damage. Inspect the intake manifold cylinder head deck for warpage.
  16.  
  17. Locate a straight edge across the intake manifold cylinder head deck surface. Position the straight edge across a minimum of two runner port openings.
  18.  
  19. Insert a feeler gauge between the intake manifold and the straight edge. A intake manifold with warpage in excess of 0.118 in. (3mm) over a 7.87 in. (200mm) area is warped and should be replaced.
  20.  

To install:

  1. Install or connect the following:

    MAP sensor
     
    EVAP solenoid, bolt, and isolator. Tighten the bolt to 89 inch lbs. (10 Nm).
     
    NEW intake manifold-to-cylinder head gaskets
     
    Intake manifold
     

  2.  
  3. Apply a 0.20 in. (5mm) band of threadlock GM P/N 12345382 or equivalent to the threads of the intake manifold bolts.

    Intake manifold bolts. Tighten intake manifold bolts first pass in sequence to 44 inch lbs. (5 Nm). Tighten intake manifold bolts final pass in sequence to 89 inch lbs. (10 Nm).

    Click image to see an enlarged view

    Fig. Lower intake manifold bolt tightening sequence-4.8L, 5.3L and 6.0L engines

     
    PCV valve and hose
     
    Coolant air bleed hose and clamp onto the throttle body
     
    Accelerator control cable bracket and bolts. Tighten the bolts to 89 inch lbs. (10 Nm).
     
    Alternator
     

  4.  

4.8L, 5.3L, 6.0L & 6.2L Engines

NOTE
The intake manifold, throttle body, fuel injection rail, and fuel injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.

  1. Remove or disconnect the following:

    Alternator
     
    Positive Crankcase Ventilation (PCV) hose and valve
     
    Manifold Absolute Pressure (MAP) sensor, if required
     
    Engine coolant air bleed clamp and hose from the throttle body
     
    Knock sensor connector, if required.
     
    Accelerator control cable bracket and bolts, if required
     
    Fuel rail with injectors, if required
     
    EVAP solenoid, bolt, and isolator
     
    Any additional engine harness attachment points and set aside
     
    Intake manifold bolts
     
    Intake manifold with gaskets
     
    Intake manifold-to-cylinder head gaskets from the manifold. Discard the intake manifold gaskets.

    Click image to see an enlarged view

    Fig. Always use new gaskets-4.8L, 5.3L, 6.0L and 6.2L engines

     

  2.  
  3. Clean the intake manifold in solvent.
  4.  
  5. Dry the intake manifold with compressed air.
  6.  
  7. Inspect the intake manifold vacuum passages for debris or restrictions.
  8.  
  9. Inspect for damaged or broken vacuum fittings, damaged MAP sensor mounting bore, or broken MAP sensor retaining tabs.
  10.  
  11. Inspect the composite intake manifold assembly for cracks or other damage.
  12.  
  13. Inspect the areas between the intake runners. Inspect all the gasket sealing surfaces for damage.
  14.  
  15. Inspect the fuel injector bores for excessive scoring or damage. Inspect the intake manifold cylinder head deck for warpage.
  16.  
  17. Locate a straight edge across the intake manifold cylinder head deck surface. Position the straight edge across a minimum of two runner port openings.
  18.  
  19. Insert a feeler gauge between the intake manifold and the straight edge. A intake manifold with warpage in excess of 0.118 in. (3mm) over a 7.87 in. (200mm) area is warped and should be replaced.
  20.  

To install:

  1. Install or connect the following:

    MAP sensor
     
    EVAP solenoid, bolt, and isolator. Tighten the bolt to 89 inch lbs. (10 Nm).
     
    NEW intake manifold-to-cylinder head gaskets
     
    Intake manifold
     

  2.  
  3. Apply a 0.20 in. (5mm) band of threadlock GM P/N 12345382 or equivalent to the threads of the intake manifold bolts.

    Intake manifold bolts. Tighten intake manifold bolts first pass in sequence to 44 inch lbs. (5 Nm). Tighten intake manifold bolts final pass in sequence to 89 inch lbs. (10 Nm).

    Click image to see an enlarged view

    Fig. Lower intake manifold bolt tightening sequence-4.8L, 5.3L, 6.0L and 6.2L engines

     
    PCV valve and hose
     
    Coolant air bleed hose and clamp onto the throttle body
     
    Accelerator control cable bracket and bolts. Tighten the bolts to 89 inch lbs. (10 Nm).
     
    Alternator
     

  4.  

5.0L, 5.7L And 7.4L Engines
  1. Remove or disconnect the following:
    NOTE
    Note the location of the manifold bolts and studs before removal for reassembly in their original positions.


    NOTE
    Do not disassemble the Central Sequential Fuel Injection (CSFI) unit.



    Negative battery cable
     
    Engine cover
     
    Air cleaner intake duct
     
    Coolant reservoir
     
    Wiring harness connectors and brackets
     
    Throttle linkage and bracket from the upper intake manifold
     
    Cruise control cable, if equipped
     
    Fuel lines and the bracket from the rear of the intake manifold
     
    Positive Crankcase Ventilation (PCV) valve and hoses
     
    Ignition coil and bracket
     
    Purge solenoid and bracket
     



    Intake manifold bolts and studs
     



    Upper intake manifold
     

  2.  
  3. Clean the old gasket residue from both mating surfaces.

    Distributor
     
    Upper radiator hose from the thermostat housing
     
    Heater hose from the lower intake manifold
     
    Coolant bypass hose
     
    Exhaust Gas Recirculation (EGR) valve
     
    Fuel pressure and return lines from the lower intake manifold
     
    Wiring harnesses and brackets from the lower manifold
     
    Left side valve cover
     
    Transmission oil level indicator and tube, if equipped
     
    EGR tube, clamp and bolt
     
    Air conditioning compressor and bracket, but do not disconnect the lines
     

  4.  
  5. Loosen the compressor mounting bracket and slide it forward, but do not remove it.

    Power brake vacuum tube
     
    Lower intake manifold bolts and lower intake manifold
     

  6.  

To install:

  1. Clean all gasket surfaces completely.
  2.  
  3. Install the intake manifold gaskets with the port blocking plates facing the rear. Factory gaskets should have the words This Side Up visible.
  4.  
  5. Apply gasket sealer to the front and rear sealing surfaces of the engine block. Extend the sealer approximately 1 / 2 inch (13mm) onto the heads.
  6.  
  7. Install the lower intake manifold.
  8.  
  9. Apply sealer to the lower intake manifold bolts prior to installation.
  10.  
  11. On the 5.0L and 5.7L engines, install the bolts and torque in sequence as follows:
    1. Step 1: 71 inch lbs. (8 Nm).
    2.  
    3. Step 2: 106 inch lbs. (12 Nm).
    4.  
    5. Step 3: 11 ft. lbs. (15 Nm).
    6.  

  12.  
  13. On the 7.4L engine, torque the bolts to 30 ft. lbs. (40 Nm) in the sequence shown.

    Click image to see an enlarged view

    Fig. Lower intake manifold bolt tightening sequence-5.0L and 5.7L engines



    Click image to see an enlarged view

    Fig. Upper and lower intake manifold bolt tightening sequence-7.4L engines

  14.  
  15. Install or connect the following:
    WARNING
    When installing the upper intake manifold be careful not to pinch the injector wires between the upper and lower intake manifolds.



    Power brake vacuum tube
     
    PCV valve and hose
     
    EGR tube, clamp and bolt
     
    Transmission oil level indicator and tube, if equipped
     
    Left side valve cover
     
    Wiring harnesses and brackets to the lower manifold
     
    Fuel pressure and return lines to the lower intake manifold
     
    EGR valve
     
    Coolant bypass hose
     
    Heater hose to the lower intake manifold
     
    Upper radiator hose to the thermostat housing
     
    Air conditioning compressor and bracket
     
    Distributor
     
    Upper intake manifold gasket
     
    Upper intake manifold
     



    Upper intake manifold mounting bolts/studs, torque in a crisscross pattern as follows:
     

    1. Step 1: Torque the bolts/studs to 44 inch lbs. (5 Nm).
    2.  
    3. Step 2: Torque the bolts/studs to 83 inch lbs. (10 Nm).

      Purge solenoid and bracket
       
      Fuel lines and the bracket at the rear of the intake manifold
       
      Ignition coil and bracket
       
      Throttle linkage and bracket to the upper intake manifold
       
      Throttle linkage cable
       
      Cruise control cable, if equipped
       
      Wiring harness connectors and brackets
       
      Air cleaner intake duct
       
      Coolant recovery reservoir and the engine cover
       
      Negative battery cable
       

    4.  

  16.  
  17. Start the vehicle and verify that there are no leaks.
  18.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Note the location of the manifold bolts and studs before removal for reassembly in their original positions.


    NOTE
    Do not disassemble the Central Sequential Fuel Injection (CSFI) unit.



    Negative battery cable
     
    Engine cover
     
    Air cleaner intake duct
     
    Coolant reservoir
     
    Wiring harness connectors and brackets
     
    Throttle linkage and bracket from the upper intake manifold
     
    Cruise control cable, if equipped
     
    Fuel lines and the bracket from the rear of the intake manifold
     
    Positive Crankcase Ventilation (PCV) valve and hoses
     
    Ignition coil and bracket
     
    Purge solenoid and bracket
     



    Intake manifold bolts and studs
     



    Upper intake manifold
     

  4.  
  5. Clean the old gasket residue from both mating surfaces.

    Distributor
     
    Upper radiator hose from the thermostat housing
     
    Heater hose from the lower intake manifold
     
    Coolant bypass hose
     
    Exhaust Gas Recirculation (EGR) valve
     
    Fuel pressure and return lines from the lower intake manifold
     
    Wiring harnesses and brackets from the lower manifold
     
    Left side valve cover
     
    Transmission oil level indicator and tube, if equipped
     
    EGR tube, clamp and bolt
     
    Positive Crankcase Ventilation (PCV) valve and hoses
     
    Air conditioning compressor and bracket, but do not disconnect the lines
     

  6.  
  7. Loosen the compressor mounting bracket and slide it forward, but do not remove it.

    Power brake vacuum tube
     
    Lower intake manifold bolts and lower intake manifold
     

  8.  

To install:

  1. Clean all gasket surfaces completely.
  2.  
  3. Install the intake manifold gaskets with the port blocking plates facing the rear. Factory gaskets should have the words This Side Up visible.
  4.  
  5. Apply gasket sealer to the front and rear sealing surfaces of the engine block. Extend the sealer approximately 1 / 2 inch (13mm) onto the heads.
  6.  
  7. Install the lower intake manifold.
  8.  
  9. Apply sealer to the lower intake manifold bolts prior to installation.
  10.  
  11. On the 5.0L and 5.7L engines, install the bolts and torque in sequence as follows:
    1. Step 1: Torque the bolts to 71 inch lbs. (8 Nm)
    2.  
    3. Step 2: Torque the bolts to 106 inch lbs. (12 Nm)
    4.  
    5. Step 3: Torque the bolts to 11 ft. lbs. (15 Nm)
    6.  

  12.  
  13. On the 7.4L engine, torque the bolts to 30 ft. lbs. (40 Nm) in the sequence shown.

    Click image to see an enlarged view

    Fig. Lower intake manifold bolt tightening sequence-5.0L and 5.7L engines



    Click image to see an enlarged view

    Fig. Upper and lower intake manifold bolt tightening sequence-7.4L engines

  14.  
  15. Install or connect the following:
    WARNING
    When installing the upper intake manifold be careful not to pinch the injector wires between the upper and lower intake manifolds.



    Power brake vacuum tube
     
    PCV valve and hose
     
    EGR tube, clamp and bolt
     
    Transmission oil level indicator and tube, if equipped
     
    Left side valve cover
     
    Wiring harnesses and brackets to the lower manifold
     
    Fuel pressure and return lines to the lower intake manifold
     
    EGR valve
     
    Coolant bypass hose
     
    Heater hose to the lower intake manifold
     
    Upper radiator hose to the thermostat housing
     
    Air conditioning compressor and bracket
     
    Distributor
     
    Upper intake manifold gasket
     
    Upper intake manifold
     



    Upper intake manifold mounting bolts/studs, torque in a crisscross pattern as follows:
     

    1. Step 1: Torque the bolts/studs to 44 inch lbs. (5 Nm)
    2.  
    3. Step 2: Torque the bolts/studs to 83 inch lbs. (10 Nm)

      Purge solenoid and bracket
       
      PCV hose
       
      Fuel lines and the bracket at the rear of the intake manifold
       
      Ignition coil and bracket
       
      Throttle linkage and bracket to the upper intake manifold
       
      Throttle linkage cable
       
      Cruise control cable, if equipped
       
      Wiring harness connectors and brackets
       
      Air cleaner intake duct
       
      Coolant recovery reservoir and the engine cover
       
      Negative battery cable
       

    4.  

  16.  
  17. Start the vehicle and verify that there are no leaks.
  18.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Note the location of the manifold bolts and studs before removal for reassembly in their original positions.


    NOTE
    Do not disassemble the Central Sequential Fuel Injection (CSFI) unit.



    Negative battery cable
     
    Engine cover
     
    Air cleaner intake duct
     
    Coolant reservoir
     
    Wiring harness connectors and brackets
     
    Throttle linkage and bracket from the upper intake manifold
     
    Cruise control cable, if equipped
     
    Fuel lines and the bracket from the rear of the intake manifold
     
    Positive Crankcase Ventilation (PCV) valve and hoses
     
    Ignition coil and bracket
     
    Purge solenoid and bracket
     



    Intake manifold bolts and studs
     



    Upper intake manifold
     

  4.  
  5. Clean the old gasket residue from both mating surfaces.

    Distributor
     
    Upper radiator hose from the thermostat housing
     
    Heater hose from the lower intake manifold
     
    Coolant bypass hose
     
    Exhaust Gas Recirculation (EGR) valve
     
    Fuel pressure and return lines from the lower intake manifold
     
    Wiring harnesses and brackets from the lower manifold
     
    Left side valve cover
     
    Transmission oil level indicator and tube, if equipped
     
    EGR tube, clamp and bolt
     
    Positive Crankcase Ventilation (PCV) valve and hoses
     
    Air conditioning compressor and bracket, but do not disconnect the lines
     

  6.  
  7. Loosen the compressor mounting bracket and slide it forward, but do not remove it.

    Power brake vacuum tube
     
    Lower intake manifold bolts and lower intake manifold
     

  8.  

To install:

  1. Clean all gasket surfaces completely.
  2.  
  3. Install the intake manifold gaskets with the port blocking plates facing the rear. Factory gaskets should have the words This Side Up visible.
  4.  
  5. Apply gasket sealer to the front and rear sealing surfaces of the engine block. Extend the sealer approximately 1 / 2 inch (13mm) onto the heads.
  6.  
  7. Install the lower intake manifold.
  8.  
  9. Apply sealer to the lower intake manifold bolts prior to installation.
  10.  
  11. On the 5.0L and 5.7L engines, install the bolts and torque in sequence as follows:
    1. Step 1: Torque the bolts to 71 inch lbs. (8 Nm)
    2.  
    3. Step 2: Torque the bolts to 106 inch lbs. (12 Nm)
    4.  
    5. Step 3: Torque the bolts to 11 ft. lbs. (15 Nm)
    6.  

  12.  
  13. On the 7.4L engine, torque the bolts to 30 ft. lbs. (40 Nm) in the sequence shown.

    Click image to see an enlarged view

    Fig. Lower intake manifold bolt tightening sequence-5.0L and 5.7L engines



    Click image to see an enlarged view

    Fig. Upper and lower intake manifold bolt tightening sequence-7.4L engines

  14.  
  15. Install or connect the following:
    WARNING
    When installing the upper intake manifold be careful not to pinch the injector wires between the upper and lower intake manifolds.



    Power brake vacuum tube
     
    PCV valve and hose
     
    EGR tube, clamp and bolt
     
    Transmission oil level indicator and tube, if equipped
     
    Left side valve cover
     
    Wiring harnesses and brackets to the lower manifold
     
    Fuel pressure and return lines to the lower intake manifold
     
    EGR valve
     
    Coolant bypass hose
     
    Heater hose to the lower intake manifold
     
    Upper radiator hose to the thermostat housing
     
    Air conditioning compressor and bracket
     
    Distributor
     
    Upper intake manifold gasket
     
    Upper intake manifold
     



    Upper intake manifold mounting bolts/studs, torque in a crisscross pattern as follows:
     

    1. Step 1: Torque the bolts/studs to 44 inch lbs. (5 Nm)
    2.  
    3. Step 2: Torque the bolts/studs to 83 inch lbs. (10 Nm)

      Purge solenoid and bracket
       
      PCV hose
       
      Fuel lines and the bracket at the rear of the intake manifold
       
      Ignition coil and bracket
       
      Throttle linkage and bracket to the upper intake manifold
       
      Throttle linkage cable
       
      Cruise control cable, if equipped
       
      Wiring harness connectors and brackets
       
      Air cleaner intake duct
       
      Coolant recovery reservoir and the engine cover
       
      Negative battery cable
       

    4.  

  16.  
  17. Start the vehicle and verify that there are no leaks.
  18.  

 
label.common.footer.alt.autozoneLogo