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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 - Upper >> Installation Procedure

Installation Procedure

WARNING: This page is about a different variant/trim than selected.
    Fig 1: Power Brake Booster Vacuum Fitting
    GM516797Courtesy of GENERAL MOTORS CORP.
  1. Install the throttle body, if removed. Refer to Throttle Body Assembly Replacement .
  2. Install the MAP sensor, if removed. Refer to Manifold Absolute Pressure (MAP) Sensor Replacement in Engine Controls-4.3L.
  3. Install the PCV valve cover, if removed, using the following procedure:
    1. Install a NEW seal (O-ring) on the PCV valve cover.
    2. Lubricate the seal with clean engine oil.
    3. Install the PCV valve cover in the upper intake manifold.
    4. Turn and lock the PCV valve cover in position.
    4. Fig 2: Locating PCV Valve Cover
    GM516804Courtesy of GENERAL MOTORS CORP.
  4. Install the power brake booster vacuum tube fitting, if removed, using the following procedure:
    1. Install a NEW seal (O-ring) on the power brake booster vacuum tube fitting.
    2. Lubricate the seal with clean engine oil.
    3. Install the power brake booster vacuum tube fitting in the upper intake manifold.
    4. Turn and lock the power brake booster vacuum tube fitting in position.
    5. Fig 3: Fuel Meter Body O-Ring Seal
    GM516773Courtesy of GENERAL MOTORS CORP.
  5. Install a NEW seal on the fuel meter body assembly.
  6. Lubricate the seal with clean engine oil.
    7. Fig 4: Intake Manifold Upper Gasket
    GM516790Courtesy of GENERAL MOTORS CORP.
  7. Install a NEW upper intake manifold to lower intake manifold gasket in the groove of the upper intake manifold.
    8. Fig 5: Upper Intake Manifold
    GM516794Courtesy of GENERAL MOTORS CORP.
  8. Install the upper intake manifold onto the lower intake manifold.
  9. If reusing the fasteners, apply Threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the upper intake manifold attaching bolts.
    10. NOTE: Refer to Fastener Notice in Cautions and Notices.
  10. Install the upper intake manifold attaching studs.

    Tighten: 

    1. Tighten the upper intake manifold attaching studs on the first pass to 5 N.m (44 lb in).
    2. Tighten the upper intake manifold attaching studs on the final pass to 9 N.m (80 lb in).

  11. Install the fuel lines to the fuel meter body assembly. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls-4.3L.
  12. Install the distributor cap. Refer to Distributor Replacement in Engine Electrical.
  13. Install the ignition control module. Refer to Ignition Control Module Replacement in Engine Electrical.
  14. Install the EVAP canister purge solenoid valve. Refer to Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement in Engine Controls-4.3L.
    15. Fig 6: View Of Accelerator Cable Bracket
    GM398027Courtesy of GENERAL MOTORS CORP.
  15. 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).

    16. Fig 7: Intake Manifold A/C Vacuum Hose
    GM374900Courtesy of GENERAL MOTORS CORP.
  16. Connect the A/C vacuum hose to the intake manifold.
  17. Install the power brake booster vacuum hose bracket and nut to the intake manifold stud.

    Tighten:  Tighten the power brake booster vacuum hose bracket nut to 11 N.m (97 lb in).

  18. Connect the power brake booster vacuum hose to the intake manifold.
    19. Fig 8: Engine Wiring Harness Bracket From Intake Manifold Stud
    GM339442Courtesy of GENERAL MOTORS CORP.
  19. Install the bracket for the engine wiring harness on the lower intake manifold stud.
  20. Install the engine wiring harness bracket nut.

    Tighten:  Tighten the engine wiring harness bracket nut to 12 N.m (106 lb in).

    21. Fig 9: Fuel Meter Body Assembly Connector, EVAP Canister Purge Solenoid Valve & Manifold Absolute Pressure Sensor
    GM532770Courtesy of GENERAL MOTORS CORP.
  21. Connect the following electrical connectors:
    • The fuel meter body assembly connector (1)
    • The EVAP canister purge solenoid valve (2)
    • The manifold absolute pressure (MAP) sensor (3)
    22. Fig 10: Throttle Position Sensor, Idle Air Control Motor, Engine Coolant Temperature Gage Sensor, & A/C High Pressure Switch
    GM532760Courtesy of GENERAL MOTORS CORP.
  22. Connect the following electrical connectors:
    • The throttle position (TP) sensor (1)
    • The idle air control (IAC) motor (2)
    • The engine coolant temperature (ECT) gage sensor (3)
    • The A/C high pressure switch (4), if equipped
    23. Fig 11: Identifying Breather Tube
    GM172995Courtesy of GENERAL MOTORS CORP.
  23. Connect the PCV valve hose assembly to the intake manifold and the valve rocker arm cover.
  24. 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.
  25. 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.
    26. Fig 12: Locating Air Cleaner Outlet Retaining Nut
    GM35885Courtesy of GENERAL MOTORS CORP.
  26. Install the air cleaner outlet duct (2) on the throttle body assembly.
  27. Tighten the retaining nut (1).

    Tighten:  Tighten the nut to 2 N.m (18 lb in).

  28. Connect the PCV tube to the air cleaner outlet duct.
  29. Position the coolant reservoir. Install the bolt.

    Tighten:  Tighten the bolt to 11 N.m (97 lb in).

  30. Install the air cleaner. Refer to Air Cleaner Assembly Replacement in Engine Controls-4.3L.
  31. Install the engine cover. Refer to Engine Cover Replacement in Interior Trim.
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