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Home >> Chevrolet >> 2005 >> Chevy Express H1500, Van Passenger >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 2 (Engine Mechanical - 4.3L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Intake Manifold Replacement - Lower >> Installation Procedure

Installation Procedure

WARNING: This page is about a different variant/trim than selected.
    Fig 1: Applying Patch Of Adhesive To Cylinder Head Side Of Intake Manifold Gasket
    GM38512Courtesy of GENERAL MOTORS CORP.
  1. Apply a 4.0 mm (0.157 in) patch of adhesive GM P/N 12346141 (Canadian P/N 10953433) or equivalent to the cylinder head side of the lower intake manifold gasket at each end.
    2. IMPORTANT: The lower intake manifold gasket must be installed while the adhesive is still wet to the touch.
  2. Install the lower intake manifold gasket onto the cylinder head.

    Use the gasket locator pins in order to properly seat the lower intake manifold gasket on the cylinder head.

    3. Fig 2: Applying Adhesive To Front Top Of Engine Block
    GM26744Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The lower intake manifold must be installed and the fasteners tightened while the adhesive is still wet to the touch.
  3. Apply a 5 mm (0.197 in) bead of adhesive GM P/N 12346141 (Canadian P/N 10953433) or equivalent to the front top of the engine block.
  4. Extend the adhesive bead 13 mm (0.50 in) onto each lower intake manifold gasket.
    5. Fig 3: Applying Adhesive To Rear Top Of Engine Block
    GM26743Courtesy of GENERAL MOTORS CORP.
  5. Apply a 5 mm (0.197 in) bead of adhesive GM P/N 12346141 (Canadian P/N 10953433) or equivalent to the rear top of the engine block.
  6. Extend the adhesive bead 13 mm (0.50 in) onto each lower intake manifold gasket.
    7. Fig 4: Intake Manifold Assembly & Bolts
    GM31510Courtesy of GENERAL MOTORS CORP.
  7. Install the lower intake manifold onto the engine block.
  8. If reusing the fasteners, apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the lower intake manifold bolts.
  9. Install the lower intake manifold bolts.
    10. Fig 5: Intake Manifold Lower Bolt Tightening Sequence
    GM188150Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  10. Tighten the lower intake manifold bolts.

    Tighten: 

    1. Tighten the bolts on the first pass in sequence (1-8) to 3 N.m (27 lb in).
    2. Tighten the bolts on the second pass in sequence (1-8) to 12 N.m (106 lb in).
    3. Tighten the bolts on the final pass in sequence (1-8) to 15 N.m (11 lb ft).

    11. Fig 6: View Of Power Steering Pump Bracket
    GM340090Courtesy of GENERAL MOTORS CORP.
  11. Position the power steering pump mounting bracket.
  12. Install the power steering pump mounting bracket, 3 bolts and the nut.

    Tighten: 

    • Tighten the power steering pump mounting bracket bolts and the nut to 41 N.m (30 lb ft).
    • Tighten the power steering pump rear bracket nut to 41 N.m (30 lb ft).
    • Tighten the power steering pump mounting bracket bolts and the nut and the power steering pump rear bracket nut to 41 N.m (30 lb ft).

  13. Install the drive belt. Refer to Drive Belt Replacement .
  14. Install the A/C compressor discharge hose from the vehicle. Refer to Discharge Hose Replacement (4.8L, 5.3L, 6.0L ) in Heating, Ventilation, and Air Conditioning.
  15. Install the A/C compressor suction hose from the vehicle. Refer to Suction Hose Replacement in Heating, Ventilation, and Air Conditioning.
    16. Fig 7: View Of Crankshaft Balancer Alignment Mark & Engine Front Cover Alignment Tab
    GM334551Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: In order to install the distributor for the correct engine timing, position the engine to number one cylinder top dead center (TDC).
  16. Remove the spark plug for number one cylinder.
  17. Rotate the crankshaft until number one cylinder is in the compression stroke.
  18. Align the 2 reference marks on the crankshaft balancer (1) and (4) with the 2 alignment marks (2) and (3) on the front cover.
  19. Install the spark plug. Refer to Spark Plug Replacement in Engine Controls-4.3L.
  20. Install the distributor. Refer to Distributor Replacement in Engine Controls-4.3L.
  21. Install the upper intake. Refer to Intake Manifold Replacement - Upper .
    22. Fig 8: View Of Accelerator Cable Bracket
    GM398027Courtesy of GENERAL MOTORS CORP.
  22. Install the accelerator control cable bracket, studs, and nuts to the intake manifold and the throttle body.

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

    23. Fig 9: Identifying Radiator Inlet Hose
    GM71614Courtesy of GENERAL MOTORS CORP.
  23. Install the water pump inlet hose to the intake manifold.
  24. Install the heater hoses. Refer to Heater Hose Replacement - Inlet and Heater Hose Replacement - Outlet in Heating, Ventilation and Air Conditioning.
  25. Install the radiator inlet hose to the water outlet. Refer to Radiator Hose Replacement - Inlet in Engine Cooling.
    26. Fig 10: Throttle Position Sensor, Idle Air Control Motor, Engine Coolant Temperature Gage Sensor, & A/C High Pressure Switch
    GM532760Courtesy of GENERAL MOTORS CORP.
  26. Connect the following electrical connectors:
    • The fuel meter body assembly connector (1)
    • The evaporative emission (EVAP) canister purge solenoid valve (2)
    • The manifold absolute pressure (MAP) sensor (3)
    • The A/C high pressure switch (4), if equipped
    27. Fig 11: A/C Compressor, Exhaust Gas Recirculation (EGR) Connector & Ground Wire
    GM532777Courtesy of GENERAL MOTORS CORP.
  27. Connect the following electrical connectors:
    • The A/C compressor clutch (1), if equipped
    • The EGR valve (2)
    • The ECT sensor (3)
  28. Install the ground wire (4) and the nut to the water outlet stud.

    Tighten:  Tighten the ground wire nut to 10 N.m (88 lb in).

  29. Install the cruise control cable, if equipped to the throttle shaft and the accelerator control cable bracket. Refer to Cruise Control Cable Replacement in Cruise Control.
  30. Install the accelerator control cable to the throttle shaft and the accelerator control cable bracket. Refer to Accelerator Controls Cable Replacement in Engine Controls-4.3L.
  31. Refill the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling.
    32. Fig 12: Water Outlet Stud Ground Wire
    GM712012Courtesy of GENERAL MOTORS CORP.
  32. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls-4.3L.
  33. Connect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  34. Install the engine cover. Refer to Engine Cover Replacement in Interior Trim.
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