Removal & Installation (C3500 HD)
WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2002 GMC Savana Special, 2002 GMC Savana Camper Special, 2002 GMC Savana, 2002 GMC C3500 HD, and 2002 Chevrolet RV Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
- Remove the upper intake manifold cover from the upper intake manifold. Disconnect both the battery negative cables from the batteries. Remove the braces from the turbocharger to the upper intake manifold. Remove the boost pressure sensor from the upper intake manifold. Remove the intake air temperature sensor from the upper intake manifold.
- Loosen the clamps on the hose between the turbocharger and the upper intake manifold. Remove the upper intake manifold from the lower intake manifold. Remove the upper intake manifold gasket from the lower intake manifold gasket.
- Apply a small amount of RTV Sealant (GM 12346286 or Canadian GM 10953472) to the hose between the turbocharger inlet and the upper intake manifold. Install the new upper intake manifold gasket. Install the air intake hose between the upper intake manifold and the turbocharger on the upper intake manifold. Install the upper intake manifold.
- To complete installation, reverse removal procedure. Tighten fasteners properly. See TORQUE SPECIFICATIONS .
NOTE:
In order to loosen the sealer, run a small screwdriver (flat blade) between the hose and the upper intake manifold. Use caution as not to damage the hose. When removing the upper intake manifold, rotate the upper intake manifold in a downward then in an upward motion to help loosen the silicone sealant on the air intake hose.