Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Refer to Fastener Notice in Cautions and Notices.

Install the intake air heater, if removed.
Tighten: Tighten the heater to 50 N.m (37 lb ft).
Install the intake manifold tube with NEW gaskets.

Fig 1: View Of Intake Manifold Tube, Gasket, Bolts & Nuts (Federal Emissions)

Courtesy of GENERAL MOTORS CORP.

Install the intake manifold tube bolts/nuts.
Tighten the intake manifold tube bolts/nuts in the order shown.
Tighten: Tighten the bolts/nuts to 9 N.m (80 lb in).

Fig 2: Intake Manifold Tube Bolt/Nut Tightening Sequence (Federal Emissions)

Courtesy of GENERAL MOTORS CORP.

Install the following fuel pipes and wiring harnesses:
- The main fuel pipes. Refer to Quick Connect Fitting(s) Service (Metal Collar) in Engine Controls - 6.6 L.
- The fuel junction block. Refer to Fuel Junction Block Replacement in Engine Controls - 6.6 L.
- The fuel hoses to the FICM and the FICM wiring harness. Refer to Fuel Injection Control Module Replacement in Engine Controls - 6.6 L.
- The fuel pipes to the left fuel rail. Refer to Fuel Rail Assembly Replacement - Bank 2 in Engine Controls - 6.6 L.
Install the intake air heater terminal and nut.
Tighten: Tighten the nut to 4 N.m (35 lb in).
Install the EGR valve. Refer to Exhaust Gas Recirculation (EGR) Valve Replacement in Engine Controls - 6.6 L.
Install the turbocharger. Refer to Turbocharger Replacement .