Corvette 1997-2005

Intake Manifold

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Removal & Installation




NOTE
The intake manifold, throttle body, fuel injectors and rail may be removed from the engine as an assembly.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Intake Air Temperature (IAT) and Mass Air Flow (MAF) sensor connectors from air intake duct and the throttle body
     
    Air intake duct
     
    Fuel rail covers
     
    Fuel line from the fuel rail
     
    Vacuum ventilation hose
     
    Fuel injector wire harness connectors
     
    Throttle Position Sensor (TPS) connector
     
    Knock Sensor (KS) connector
     
    All other connections from the intake manifold
     
    KS jumper pigtail from the fuel rail stop bracket
     
    Positive Crankcase Ventilation (PCV) valve pipe from the left valve rocker arm cover
     
    PCV valve pipe from the right side valve rocker arm cover
     
    PCV tube from the throttle body
     
    Engine cooling air bleed hose from the throttle body
     
    Throttle body heater outlet hose
     
    Intake manifold
     

  8.  

To install:

  1. Apply a 0.20 in. (5mm) bead of threadlock to the threads of the intake manifold bolts.
    CAUTION
    The fuel rail stop bracket must be installed on the intake manifold in its original position. Failure to reinstall this part may result in fuel spray causing personal injury.

  2.  
  3. Install or connect the following:

    New gaskets on the cylinder heads and engine
     
    Intake manifold on the engine
     
    Fuel stop bracket
     
    Intake manifold bolts. Torque the bolts first to 44 inch lbs. (5 Nm) in the sequence shown. Then, make a second pass and tighten the bolts to 89 inch lbs. (8 Nm) using the same sequence.

    Click image to see an enlarged view

    Fig. Intake manifold torque sequence-5.7L engine



    Click image to see an enlarged view

    Fig. Be sure to reinstall the fuel stop bracket when installing the intake manifold

     
    MAP sensor
     
    Throttle body heater outlet hose
     
    Engine bleed air bleed hose to the throttle body
     
    PCV tube to the throttle body
     
    PCV valve pipe to the right side rocker arm cover
     
    PCV pipe to the left side rocker arm cover
     
    KS sensor jumper pigtail to the fuel rail bracket
     
    KS connector
     
    TPS connector
     
    Fuel injector wire harness connector
     
    Vacuum vent hose
     
    Fuel line to the fuel rail
     
    Fuel rail cover
     
    Air intake duct
     
    IAT and MAF sensor connectors to the throttle body and the air intake duct
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the vehicle and check for leaks, repair if necessary.
  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Engine sight covers
     
    Fuel injector electrical connectors
     
    Throttle body electrical connectors
     
    Fuel supply line for the fuel injectors
     
    Fuel rail
     
    Brake booster vacuum hose
     
    Manifold absolute pressure (MAP) sensor
     
    Evaporative emission (EVAP) valve and tube assembly from the intake manifold assembly
     
    Intake manifold mounting bolts and fuel rail stop bracket
     
    Intake manifold and gaskets
     

  8.  

To install:


WARNING
Do not reuse the intake manifold gaskets.

  1. Install new intake manifold gaskets.
  2.  
  3. Install the intake manifold.
  4.  
  5. Install the fuel rail stop bracket.
  6.  
  7. Apply a 5 mm (0.2 inch) band of threadlocker to the threads of the intake manifold bolts
  8.  
  9. Install the intake manifold bolts and tighten in sequence as follows:
    1. Step 1: Tighten to 44 inch lbs. (5 Nm).
    2.  
    3. Step 2: Tighten to 89 inch lbs. (10 Nm).

      Click image to see an enlarged view

      Fig. Intake manifold torque sequence

    4.  

  10.  
  11. Install or connect the following:

    MAP sensor
     
    EVAP valve and tube assembly to the intake assembly. Tighten the mounting bolt to 37 ft. lbs. (50 Nm)
     
    Install the EVAP tubes
     
    Fuel rail and fuel supply hose
     
    Brake booster vacuum hose
     
    Throttle body electrical connectors
     
    Fuel injector electrical connectors
     
    Engine sight covers
     
    Negative battery cable
     

  12.  
  13. Refill the cooling system to the correct level.
  14.  
  15. Start the engine and check for leaks.
  16.  

5.7L Engines

NOTE
The intake manifold, throttle body, fuel injectors and rail may be removed from the engine as an assembly.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Engine sight covers
     
    Fuel feed hose
     
    Evaporative Emission (EVAP) canister purge tube from the intake manifold
     
    EVAP canister purge tube from the EVAP canister purge solenoid valve
     
    EVAP canister purge tube
     
    EVAP canister purge tube from the EVAP canister purge solenoid valve
     
    Disconnect the EVAP canister purge tube from the fuel feed pipe
     
    EVAP canister purge tube
     
    Throttle Position (TP) sensor connector
     
    Coolant air bleed hose
     
    Throttle body heater outlet hose
     
    Fuel injector electrical connectors
     
    EVAP canister purge solenoid valve connector
     
    Electronic Throttle Control (ETC) connector
     
    EVAP canister purge solenoid valve from the bracket
     
    Harness clips at the fuel rails
     
    Power brake booster vacuum hose at the booster
     
    Knock Sensor (KS) wire harness clip from the fuel rail stop bracket
     
    TP sensor harness clip from the Positive Crankcase Ventilation (PCV) tube
     
    PCV tube from the right rocker arm cover and throttle body
     
    PCV valve pipe from the left rocker arm cover, if equipped with the VIN G engine
     
    PCV valve pipe strap nut, if equipped with the VIN G engine
     
    PCV valve pipe from the right rocker arm cover and intake manifold
     
    PCV valve hose from the valley cover and intake manifold, if equipped with the VIN S engine
     
    Intake manifold bolts and fuel rail stop bracket
     

  8.  
  9. Position the intake manifold forward.

    Manifold Absolute Pressure (MAP) sensor vacuum hose
     
    MAP sensor connector
     
    Intake manifold
     
    Intake manifold gaskets and discard
     

  10.  

To install:

  1. Install or connect the following:

    New intake manifold gaskets
     
    Intake manifold
     

  2.  
  3. Position the intake manifold forward.

    MAP sensor vacuum hose
     
    MAP sensor connector
     

  4.  
  5. Position the intake manifold into place.
  6.  
  7. Apply threadlock GM P/N 12345382 to the threads of the intake manifold bolts.
    CAUTION
    The fuel rail stop bracket must be installed onto the engine assembly. The stop bracket serves as a protective shield for the fuel rail in the event of a vehicle frontal crash. If the fuel rail stop bracket is not installed and the vehicle is involved in a frontal crash, fuel could be sprayed possibly causing a fire and personal injury from burns.

  8.  
  9. Install or connect the following:

    Fuel rail stop bracket
     
    Intake manifold bolts
     

  10.  
  11. Tighten the intake manifold bolts as follows:
    1. Step 1: in sequence to 44 inch lbs. (5 Nm).
    2.  
    3. Step 2: in sequence to 89 inch lbs. (10 Nm).

      Click image to see an enlarged view

      Fig. Intake manifold torque sequence-All engines



      Click image to see an enlarged view

      Fig. Be sure to reinstall the fuel stop bracket when installing the intake manifold

    4.  

  12.  
  13. Install or connect the following:

    PCV valve hose to the valley cover and intake manifold, if equipped
     
    PCV valve pipe to the right valve rocker arm cover and intake manifold, if equipped
     
    PCV pipe strap nut and tighten to 106 inch lbs. (12 Nm)
     
    PCV valve pipe to the left rocker arm cover, if equipped
     
    PCV tube to the right rocker arm cover
     
    TP sensor harness clip to the PCV tube
     
    KS wire harness to the fuel rail stop bracket
     
    Power brake booster vacuum hose to the booster
     
    Intake manifold branches of the wiring harness
     
    Harness clips at the fuel rails
     
    EVAP canister purge solenoid valve to the bracket
     
    ETC connector
     
    EVAP canister purge solenoid valve connector
     
    Fuel injector connectors
     
    Throttle body heater outlet hose
     
    Throttle body heater outlet hose to the throttle body
     
    Throttle body heater outlet hose clamp at the throttle body
     
    Coolant air bleed hose
     
    TP sensor connector
     
    EVAP canister purge tube
     
    EVAP canister purge tube to the fuel feed pipe
     
    EVAP canister purge tube to the EVAP canister purge solenoid valve
     
    EVAP canister purge tube
     
    EVAP canister purge tube to the EVAP canister purge solenoid valve
     
    EVAP canister purge tube to the intake manifold
     
    Fuel feed hose
     
    Fuel rail covers
     
    Negative battery cable
     

  14.  
  15. Fill the cooling system.
  16.  
  17. Start the vehicle and check for leaks, repair if necessary.
  18.  

6.0L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Engine sight covers
     
    Fuel injector electrical connectors
     
    Throttle body electrical connectors
     
    Fuel supply line for the fuel injectors
     
    Fuel rail
     
    Brake booster vacuum hose
     
    Manifold absolute pressure (MAP) sensor
     
    Evaporative emission (EVAP) valve and tube assembly from the intake manifold assembly
     
    Intake manifold mounting bolts
     
    Fuel rail stop bracket
     
    Intake manifold and gaskets
     

  8.  

To install:


WARNING
Do not reuse the intake manifold gaskets.

  1. Install new intake manifold gaskets.
  2.  
  3. Install the intake manifold.
  4.  
  5. Install the fuel rail stop bracket.
  6.  
  7. Install the intake manifold bolts and tighten in sequence as follows:
    1. Step 1: Tighten to 44 inch lbs.
    2.  
    3. Step 2: Tighten to 89 inch lbs.

      Click image to see an enlarged view

      Fig. Intake manifold torque sequence-All engines

    4.  

  8.  
  9. Install or connect the following:

    MAP sensor
     
    EVAP valve and tube assembly to the intake assembly. Tighten the mounting bolt to 37 ft. lbs. (50 Nm).
     
    Fuel rail and fuel supply hose
     
    Brake booster vacuum hose
     
    Throttle body electrical connectors
     
    Fuel injector electrical connectors
     
    Engine sight covers
     
    Negative battery cable
     

  10.  
  11. Refill the cooling system to the correct level.
  12.  
  13. Start the engine and check for leaks.
  14.  

 
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