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Home >> Chevrolet >> 2001 >> Venture Base, Van Passenger >> Repair and Diagnosis >> External Pages >> Different car >> Section 655 (Engine Mechanical - 5.7L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Intake Manifold Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2003 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.

Important:  DO NOT reuse the intake manifold gaskets. Install NEW intake manifold gaskets.

  1. Install NEW intake manifold gaskets (1) to the manifold.
    Fig 1: Installing New Intake Manifold Gaskets
    G01970407Courtesy of GENERAL MOTORS CORP.
  2. Install intake manifold.
  3. Position the intake manifold forward.
    Fig 2: Installing Intake Manifold
    G01970408Courtesy of GENERAL MOTORS CORP.
  4. Connect the MAP sensor vacuum hose.
  5. Connect the MAP sensor (3) electrical connector.
  6. Position the intake manifold into place.
    Fig 3: Connecting MAP Sensor Electrical Connector
    G01970409Courtesy of GENERAL MOTORS CORP.
  7. Apply threadlock GM U.S. P/N 12345382, Canada P/N 10953489, or equivalent to the threads of the intake manifold bolts (1).
    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. Install the fuel rail stop bracket (2).
  9. Install the intake manifold bolts (1).
    Fig 4: Installing Fuel Rail Stop Bracket, And Intake Manifold Bolts
    G01970410Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to FASTENER NOTICE .
  10. Tighten the intake manifold bolts.

    Tighten 

    1. 10.1. Tighten the intake manifold bolts a first pass in sequence to 5 N.m (44 lb in).
    2. 10.2. Tighten the intake manifold bolts a final pass in sequence to 10 N.m (89 lb in).
    Fig 5: Intake Manifold Bolts Tightening Sequence
    G01970411Courtesy of GENERAL MOTORS CORP.
  11. If equipped with the RPO LS6 engine, install the PCV valve hose (1) to the valley cover and intake manifold.
    Fig 6: Installing PCV Valve Hose
    G01970412Courtesy of GENERAL MOTORS CORP.
  12. If equipped with the RPO LS1 engine, install the PCV valve pipe to the right valve rocker arm cover and intake manifold.
  13. Install the PCV pipe strap nut.

    Tighten 

    Tighten the PCV pipe strap nut to 12 N.m (106 lb in).

    Fig 7: Installing PCV Valve Pipe To Right Valve Rocker Arm Cover And Intake Manifold
    G01970413Courtesy of GENERAL MOTORS CORP.
  14. If equipped with the RPO LS1 engine, install the PCV valve pipe to the left rocker arm cover.
    Fig 8: Installing PCV Valve Pipe To Left Rocker Arm Cover
    G01970414Courtesy of GENERAL MOTORS CORP.
  15. Install the PCV tube to the right rocker arm cover.
  16. Install the TP sensor harness clip to the PCV tube.
    Fig 9: Installing PCV Tube To Right Rocker Arm Cover
    G01970415Courtesy of GENERAL MOTORS CORP.
  17. Install the knock sensor wire harness (1) to the fuel rail stop bracket (2).
    Fig 10: Installing Knock Sensor Wire Harness To Fuel Rail Stop Bracket
    G01970416Courtesy of GENERAL MOTORS CORP.
  18. Connect the power brake booster vacuum hose to the booster.
    Fig 11: Connecting Power Brake Booster Vacuum Hose To Booster
    G01970417Courtesy of GENERAL MOTORS CORP.
  19. Position the intake manifold branches of the wiring harness.
  20. Connect the harness clips at the fuel rails.
  21. Install the EVAP canister purge solenoid valve from the bracket.
    Fig 12: Installing EVAP Canister Purge Solenoid Valve
    G01970418Courtesy of GENERAL MOTORS CORP.
  22. Connect the ETC electrical connector (3).
  23. Connect the EVAP canister purge solenoid valve electrical connector (2).
  24. Connect all the fuel injector electrical connectors (1).
    Fig 13: Connecting Electrical Connectors
    G01970419Courtesy of GENERAL MOTORS CORP.
  25. Install the throttle body heater outlet hose.
    Fig 14: Installing Throttle Body Heater Outlet Hose
    G01970420Courtesy of GENERAL MOTORS CORP.
  26. Install the throttle body heater outlet hose to the throttle body.
  27. Position the throttle body heater outlet hose clamp at the throttle body.
  28. Install the coolant air bleed hose. Refer to COOLANT AIR BLEED HOSE REPLACEMENT in Engine Cooling.
  29. Connect the TP sensor electrical connector.
    Fig 15: Connecting TP Sensor Electrical Connector
    G01970421Courtesy of GENERAL MOTORS CORP.
  30. Install the EVAP canister purge tube.
  31. Connect the EVAP canister purge tube to the fuel feed pipe.
  32. Connect the EVAP canister purge tube to the EVAP canister purge solenoid valve.
    Fig 16: Installing EVAP Canister Purge Tube To Fuel Feed Pipe
    G01970422Courtesy of GENERAL MOTORS CORP.
  33. Install the EVAP canister purge tube.
  34. Connect the EVAP canister purge tube to the EVAP canister purge solenoid valve.
  35. Connect the evaporative emission (EVAP) canister purge tube to the intake manifold.
  36. Install the fuel feed hose. Refer to FUEL LINE DISCONNECT FITTINGS .
    Fig 17: Installing EVAP Canister Purge Tube To EVAP Canister Purge Solenoid Valve
    G01970423Courtesy of GENERAL MOTORS CORP.
  37. Install the left fuel rail cover.
    Fig 18: Installing Left Fuel Rail Cover
    G01970424Courtesy of GENERAL MOTORS CORP.
  38. Install the right fuel rail cover.
    Fig 19: Installing Right Fuel Rail Cover
    G01970425Courtesy of GENERAL MOTORS CORP.
  39. If replacing the intake manifold, perform the following:
  40. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
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