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Home >> Chevrolet >> 2007 >> Chevy Express G2500, Van Cargo, 6.6 6 >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 23 (Engine Mechanical - 4.8L, 5.3L, And 6.0L (2 Of 4)) >> On-Vehicle REPARI Instructions >> Intake Manifold Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different variant/trim than selected.
    Fig 1: View Of Intake Manifold Gasket
    GM492770Courtesy of GENERAL MOTORS CORP.
  1. Install new intake manifold gaskets (1) to the intake manifold.
    2. Fig 2: View Of Intake Manifold & Bolts
    GM1201541Courtesy of GENERAL MOTORS CORP.
  2. Install the intake manifold.
  3. Apply a 5 mm (0.20 in) band of threadlock to the threads of the intake manifold bolts. Refer to Sealers, Adhesives, and Lubricants for the correct part number.
    4. Fig 3: Identifying Intake Manifold Bolt Tightening Sequence
    GM63222Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice .
  4. Install the intake manifold bolts.

    Tighten: 

    1. Tighten the intake manifold bolts a first pass in sequence to 5 N.m (44 lb in).
    2. Tighten the intake manifold bolts a final pass in sequence to 10 N.m (89 lb in).

    5. Fig 4: View Of EVAP Purge Solenoid Bolt, Solenoid & Isolator
    GM389993Courtesy of GENERAL MOTORS CORP.
  5. Install the EVAP purge solenoid (3), isolator (1), and bolt (2) to the intake manifold.

    Tighten:  Tighten the EVAP purge solenoid bolt to 10 N.m (89 lb in).

    6. Fig 5: View Of EVAP Purge Solenoid Vent Tube
    GM372717Courtesy of GENERAL MOTORS CORP.
  6. Install the EVAP purge solenoid vent tube to the solenoid (1) and vapor pipe.
  7. Install the engine coolant air bleed clamp and hose to the throttle body, if applicable.
    8. Fig 6: Intake Manifold MAP Sensor
    GM260159Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Lightly coat the MAP sensor seal with clean engine oil before installing.
  8. Install the MAP sensor (1) to the intake manifold.
    9. Fig 7: View Of PCV Hose
    GM1201537Courtesy of GENERAL MOTORS CORP.
  9. Install the PCV hose.
    10. Fig 8: View Of MAP Sensor & Knock Sensor Electrical Connectors
    GM679510Courtesy of GENERAL MOTORS CORP.
  10. Connect the knock sensor harness electrical connector to the intake manifold.
  11. Connect the following electrical connectors.
    • MAP sensor (1)
    • Knock sensor (2)
    • exhaust gas recirculation (EGR) valve, if equipped
  12. Install the fuel injectors. Refer to Fuel Injector Replacement .
  13. Install the throttle body. Refer to Throttle Body Assembly Replacement .
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