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Intake Manifold: Installation

WARNING: This page is about a different car, the 2003 GMC Sierra, 2003 GMC Cab & Chassis Sierra, 2003 Chevrolet Silverado, and 2003 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Always apply a few drops of clean engine oil to the male pipe ends before connecting the fuel pipe fittings in order to reduce the risk of fire and personal injury. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.
  1. Install a new "O" ring seal to the fuel meter body. Install a new upper intake manifold gasket. Install the upper intake manifold. If reusing the old throttle body/intake manifold studs, apply GM threadlock US (12345382) or Canada (10953489), or equivalent to the threads.
  2. Install the front two throttle body studs. Install the upper intake manifold studs and tighten to specification. See TORQUE SPECIFICATIONS .
  3. Install the accelerator cable bracket. Install the accelerator cable bracket nuts and tighten to specification. Connect the power brake booster vacuum hose to the vacuum fitting. Install the PCV valve hose to the valve cover and rocker cover.
  4. Position the engine wiring harness and bracket. Install the engine wiring harness bracket stud and Tighten to specification. Install the engine wiring harness rear bracket nut at the EVAP canister purge solenoid valve. Tighten the nut to specification.
  5. Install the engine wiring harness ground nut and ground wire to the rear of the right cylinder head and tighten to specification. Install the engine wiring harness bracket. Install the engine wiring harness bracket nuts and tighten to specification.
  6. Connect the EVAP canister harness to the purge solenoid valve. Connect the EVAP canister purge solenoid valve and MAP sensor electrical connectors. Connect the TP sensor, IAC motor and control port injector module electrical connectors.
  7. Install the engine wiring harness clip bolt and tighten to specification. Position the bracket and cables. Install the accelerator control cable bracket with the cables attached, to the throttle body. Install the accelerator control cable bracket nuts and tighten to specification.
  8. Connect the A/C compressor clutch and A/C pressure switch electrical connectors, if equipped. Install the engine wiring harness clip to the accelerator control cable bracket.
  9. Install the accelerator cable to the throttle body lever. Connect the cruise control cable to the throttle lever, if equipped. Install the following new components to the fuel meter body: Lower fuel seals, spacer rings, upper fuel seals and fuel seal retainers.
  10. Apply a few drops of clean engine oil to the fuel feed/return pipe ends. Install the fuel feed/return pipes to the fuel meter body. Install the fuel feed/return pipe bracket. Install the fuel feed/return pipe bracket nuts.
  11. Install the fuel feed/return pipe bolt and nuts. Tighten the bolt to specification. Tighten the nuts to specification. Remove the cap from the fuel pipes.
  12. Install new "O" rings on the fuel feed/return pipes. Connect the fuel feed/return pipes to the engine compartment pipes. Tighten the fittings to specification.
  13. Test the system for leaks using the following procedure: Turn the ignition on, with the engine off for 2 seconds. Turn the ignition off for 10 seconds. Turn the ignition on, with the engine off. Inspect for fuel leaks.
  14. Install the air cleaner resonator outlet duct. See AIR CLEANER RESONATOR OUTLET DUCT .
Fig 1: Locating Fuel Line Fittings & Fuel Line Bracket (4.3L)
G00143842Courtesy of GENERAL MOTORS CORP.
Fig 2: Identifying Fuel Feed/Return Pipes to Fuel meter Components (4.3L)
G00232218Courtesy of GENERAL MOTORS CORP.
Fig 3: Removing/Installing Accelerator Control Cable Routing Bracket (4.3L)
G00143850Courtesy of GENERAL MOTORS CORP.
Fig 4: Locating Fuel Meter Body Assembly, IAC Motor & TP Sensor Electrical Connectors (4.3L)
G00232219Courtesy of GENERAL MOTORS CORP.
Fig 5: Removing PCV Hose Assembly (4.3L)
G00209127Courtesy of GENERAL MOTORS CORP.
Fig 6: Removing/Installing Accelerator Control Cable Bracket (4.3L)
G00143851Courtesy of GENERAL MOTORS CORP.


  1. Install new intake manifold gaskets to the intake manifold. Install the intake manifold.
  2. Apply a 0.20" (5 mm) band of GM threadlock US (12345382) or Canada (10953489), or equivalent to the threads of the intake manifold bolts.
  3. Tighten the intake manifold bolts. See Fig 4. See TORQUE SPECIFICATIONS .
  4. Install the EVAP purge solenoid, isolator, and bolt to the intake manifold. Tighten the EVAP purge solenoid bolt to specification. Install the EVAP purge solenoid vent tube to the solenoid and vapor pipe.
  5. Lightly coat the MAP sensor seal with clean engine oil. Install the MAP sensor to the intake manifold. Install the PCV hose with valve.
  6. If equipped with vacuum assisted brakes, install the vacuum brake booster hose to the rear of the intake manifold. Route the electrical harness into position over the engine.
  7. Connect the knock sensor harness electrical connector to the intake manifold. Connect the MAP sensor and Knock sensor electrical connectors.
  8. Install the fuel injectors. See FUEL INJECTORS  under FUEL SYSTEMS. Install the throttle body. See THROTTLE BODY .
Fig 1: Removing Knock And MAP Sensor Harness Connectors (4.8L, 5.3L & 6.0L)
G00232229Courtesy of GENERAL MOTORS CORP.
Fig 2: Removing PCV Hose With Valve (4.8L, 5.3L & 6.0L)
G00232230Courtesy of GENERAL MOTORS CORP.
Fig 3: Removing Intake Manifold (4.8L, 5.3L & 6.0L)
G00232231Courtesy of GENERAL MOTORS CORP.
Fig 4: Intake Manifold Bolt Tightening Sequence (4.8L, 5.3L & 6.0L)
G00232213Courtesy of GENERAL MOTORS CORP.
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