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Home >> Chevrolet >> 2001 >> Venture Base, Van Passenger >> Repair and Diagnosis >> External Pages >> Different car >> Section 516 (Engine Mechanical - 4.3L (LU3)) >> Repair Instructions >> On-Vehicle Repair Instructions >> Intake Manifold Replacement - Upper >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2003 GMC Sonoma, 2003 GMC Jimmy, 2003 Chevrolet S10 Pickup, and 2003 Chevrolet Blazer. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the throttle body, if removed. Refer to THROTTLE BODY in Removal and Installation in Engine Performance.
  2. Install the MAP sensor, if removed. Refer to MANIFOLD ABSOLUTE PRESSURE SENSOR in Removal and Installation in Engine Performance.
  3. Install the PCV valve cover, if removed, using the following procedure:
    1. 3.1. Install a NEW seal (O-ring) on the PCV valve cover.
    2. 3.2. Lubricate the seal with clean engine oil.
    3. 3.3. Install the PCV valve cover in the upper intake manifold.
    4. 3.4. Turn and lock the PCV valve cover in position.
      Fig 1: PCV Valve Cover
      G01977394Courtesy of GENERAL MOTORS CORP.
  4. Install the power brake booster vacuum tube fitting, if removed, using the following procedure:
    1. 4.1. Install a NEW seal (O-ring) on the power brake booster vacuum tube fitting.
    2. 4.2. Lubricate the seal with clean engine oil.
    3. 4.3. Install the power brake booster vacuum tube fitting in the upper intake manifold.
    4. 4.4. Turn and lock the power brake booster vacuum tube fitting in position.
      Fig 2: Power Brake Booster Vacuum Tube
      G01977395Courtesy of GENERAL MOTORS CORP.
  5. Install a NEW seal on the fuel meter body assembly.
  6. Lubricate the seal with clean engine oil.
    Fig 3: Fuel Meter Body Assembly Seal
    G01977396Courtesy of GENERAL MOTORS CORP.
  7. Install a NEW upper intake manifold to lower intake manifold gasket in the groove of the upper intake manifold.
    Fig 4: Upper Intake Manifold And Lower Intake Manifold Gasket
    G01977397Courtesy of GENERAL MOTORS CORP.
  8. Install the upper intake manifold onto the lower intake manifold.
  9. If reusing the fasteners, apply threadlock GM P/N 12345382 or equivalent to the threads of the upper intake manifold attaching bolts.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  10. Install the upper intake manifold attaching studs.

    Tighten 

    1. 10.1. Tighten the upper intake manifold attaching studs on the first pass to 5 N.m (44 lb in).
    2. 10.2. Tighten the upper intake manifold attaching studs on the final pass to 9 N.m (80 lb in).
  11. Install the fuel lines to the fuel meter body assembly.
  12. Install the EVAP canister purge solenoid valve. Refer to EVAP CANISTER in Removal and Installation in Engine Performance.
  13. Install the bracket for the engine wiring harness on the lower intake manifold stud.
  14. Install the engine wiring harness bracket nut.

    Tighten 

    Tighten the engine wiring harness bracket nut to 12 N.m (106 lb in).

    Fig 5: Upper and Lower Intake Manifolds
    G01977398Courtesy of GENERAL MOTORS CORP.
    Fig 6: Engine Wiring Harness Bracket
    G01977399Courtesy of GENERAL MOTORS CORP.
  15. Install the accelerator and cruise control cable bracket to the throttle body.
  16. Install the accelerator and cruise control cable bracket nuts.

    Tighten 

    Tighten the accelerator and cruise control cable bracket nuts to 9 N.m (80 lb in).

    Fig 7: Accelerator and Cruise Control Cable Bracket
    G01977400Courtesy of GENERAL MOTORS CORP.
  17. Install the accelerator control cable bracket to the throttle body and the intake manifold.

    Tighten 

    Tighten the accelerator control cable bracket studs and nuts to 12 N.m (106 lb in).

    Fig 8: Accelerator Control Cable Bracket
    G01977401Courtesy of GENERAL MOTORS CORP.
  18. Connect the PCV valve hose assembly to the intake manifold and the valve rocker arm cover.
    Fig 9: View of PCV Valve Hose
    G01977402Courtesy of GENERAL MOTORS CORP.
  19. Position the engine wiring harness.
  20. Install the wire harness clip to the accelerator cable bracket.
  21. Connect the following electrical connectors:
    • The fuel meter body assembly (1)
    • The manifold absolute pressure (MAP) sensor (3)
    • The EVAP canister purge solenoid valve (2)
      Fig 10: Disconnecting Electrical Connectors
      G01977403Courtesy of GENERAL MOTORS CORP.
  22. Connect the following electrical connectors:
    • The A/C compressor clutch (1)
    • The A/C compressor cutoff switch (5), if equipped
    • The throttle position (TP) sensor (2)
    • The idle air control (IAC) motor (3)
      Fig 11: Disconnecting Electrical Connectors
      G01977404Courtesy of GENERAL MOTORS CORP.
  23. Connect the vacuum hose from the vacuum tank to the intake manifold.
  24. Install the power brake booster vacuum hose to the intake manifold.
  25. Install the cruise control cable, if equipped to the throttle shaft and the bracket. Refer to or CRUISE CONTROL CABLE REPLACEMENT (4.3L) in Cruise Control.
    Fig 12: View of Cruise Control Cable
    G01977405Courtesy of GENERAL MOTORS CORP.
  26. Install the accelerator cable onto the throttle body.
    Fig 13: View of Accelerator Cable
    G01977406Courtesy of GENERAL MOTORS CORP.
  27. Wrap the cable in between the finger of the hook tab and the pulley wall. Make sure that the cable is fully seated in the pulley groove. The cable must not lie outside of the hook tab.
    Fig 14: Seating Pulley in Groove
    G01977407Courtesy of GENERAL MOTORS CORP.
  28. Install the accelerator cable to the accelerator cable control bracket.
    Fig 15: Installing Accelerator Cable to Control Bracket
    G01977408Courtesy of GENERAL MOTORS CORP.
    NOTE:
    • Handle the MAF sensor carefully.
    • Do not drop the MAF sensor in order to prevent damage to the MAF sensor.
    • Do not damage the screen located on the air inlet end of the MAF.
    • Do not touch the sensing elements.
    • Do not allow solvents and lubricants to come in contact with the sensing elements.
    • Use a small amount of a soap based solution in order to aid in the installation.
  29. Install air cleaner outlet duct to throttle body.
  30. Install air cleaner outlet duct to MAF sensor.

    Tighten 

    Fig 16: View of MAF Sensor
    G01977409Courtesy of GENERAL MOTORS CORP.

    Tighten the hose clamp to 4 N.m (32 lb in).

  31. Connect the IAT sensor harness connector.
    Fig 17: View of IAT Sensor Harness Connector
    G01977410Courtesy of GENERAL MOTORS CORP.
  32. Install the air cleaner outlet duct retaining wingnut.

    Tighten 

    Tighten the wingnut to 2 N.m (18 lb in).

    Fig 18: Installing Air Cleaner Outlet Duct Retaining Wingnut
    G01977411Courtesy of GENERAL MOTORS CORP.
  33. Connect the breather tube to the air cleaner outlet duct.
    Fig 19: Connecting Breather Tube to Air Cleaner Outlet Duct
    G01977412Courtesy of GENERAL MOTORS CORP.
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