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Home >> Chevrolet >> 2022 >> Tahoe PPV, RWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 15 (Engine Mechanical - 3.0L (Lm2) Diesel - Repair Instructions (1 Of 11)) >> Repair Instructions >> Intake Manifold Replacement >> Installation Procedure

Installation Procedure

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  1. GM5136785Courtesy of GENERAL MOTORS COMPANY

    Intake Manifold Gasket (3) - Install NEW [6x]

  2. Intake Manifold (1) - Install
  3. Intake Manifold Bolt (2) - Install and hand tighten [9x]
    4. CAUTION:

    Refer to Fastener Caution .

  4. Intake Manifold Bolt (2) - Tighten in sequence [9x] - Fastener Specifications
  5. GM5136780Courtesy of GENERAL MOTORS COMPANY

    Intake Manifold Insulator (1) - Install

  6. Intake Manifold Insulator Retainer (2) - Install [2x]
  7. GM5203874Courtesy of GENERAL MOTORS COMPANY

    Position the engine wiring harness channel (3) at the front of the engine, attach retainer at intake manifold, and connect electrical connectors as needed.

  8. Engine Wiring Harness Bracket Bolt (2) - Install and tighten - Fastener Specifications
  9. Engine Wiring Harness Bracket Nut (1) - Install and tighten [2x] - Fastener Specifications
  10. GM5628860Courtesy of GENERAL MOTORS COMPANY

    Install a NEW exhaust gas recirculation pipe gasket (3).

  11. Install a NEW exhaust gas recirculation pipe seal (2).
  12. Install the exhaust gas recirculation pipe (1).
  13. GM5208251Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Note: Support the exhaust gas recirculation pipe when loosening/tightening the bolts to ensure the pipe is not deformed.

    Install and hand tighten the 2 exhaust gas recirculation pipe bolts (1).

  14. GM5206053Courtesy of GENERAL MOTORS COMPANY

    Turbocharger Coolant Feed and Return Pipe Bolt (3) - Install and tighten - Fastener Specifications

  15. Turbocharger Coolant Return Hose (2) @ Turbocharger Coolant Feed Pipe - Install
  16. Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
  17. GM5204428Courtesy of GENERAL MOTORS COMPANY

    Exhaust Gas Recirculation Outlet Pipe Bolt (1) - Install and tighten [2x] - Fastener Specifications .

  18. GM5204427Courtesy of GENERAL MOTORS COMPANY

    Exhaust Gas Recirculation Outlet Pipe Bolt (2) - Install and tighten - Fastener Specifications

  19. Install the turbocharger coolant return hose clip (1).
  20. GM5204431Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Support the exhaust gas recirculation pipe when loosening/tightening the bolts to ensure the pipe is not deformed.

    Exhaust Gas Recirculation Cooler Bolt (1) - Install and tighten [2x] - Fastener Specifications .

  21. GM5620997Courtesy of GENERAL MOTORS COMPANY

    Engine Coolant Air Bleed Hose (2) - Reposition

  22. Engine Coolant Outlet Pipe Bracket Bolt (1) - Install and tighten - Fastener Specifications
  23. GM5170071Courtesy of GENERAL MOTORS COMPANY

    Install the rear engine wiring harness channel (2).

  24. Engine Wiring Harness Bracket Nut (1) - Install and tighten [3x] - Fastener Specifications .
  25. GM5613883Courtesy of GENERAL MOTORS COMPANY

    Intake Air Pressure and Temperature Sensor (2) - Install

  26. Intake Air Pressure and Temperature Sensor Bolt (1) - Install and tighten - Fastener Specifications
  27. Connect the intake air pressure and temperature sensor electrical connector.
  28. GM5135048Courtesy of GENERAL MOTORS COMPANY

    Oil Level Indicator Tube O-Ring (2) @ Oil Level Indicator Tube - Install NEW

  29. Oil Level Indicator Tube (1) @ Lower Crankcase Extension - Install
  30. GM5485778Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    With aid of assistant reposition the engine wiring harness and note the routing of oil level indicator tube.

    Oil Level Indicator Tube (2) - Install

  31. Oil Level Indicator Tube Bolt (1) - Install and tighten - Fastener Specifications
  32. GM5485779Courtesy of GENERAL MOTORS COMPANY

    Engine Oil Level Indicator (1) - Install

  33. GM5136778Courtesy of GENERAL MOTORS COMPANY

    Connect electrical connector and clip the glow plug wiring harness (1) to the intake manifold.

  34. GM5136775Courtesy of GENERAL MOTORS COMPANY

    Clip the engine coolant temperature sensor wiring harness (1) to the intake manifold.

  35. GM5635807Courtesy of GENERAL MOTORS COMPANY

    Exhaust Gas Recirculation Coolant Return Pipe (4) - Install

  36. Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
  37. Thermostat Bypass Pipe Bolt (3) - Install and tighten - Fastener Specifications
  38. Wiring Harness Retainer (2) @ Exhaust Gas Recirculation Coolant Return Pipe - Install
  39. GM5635616Courtesy of GENERAL MOTORS COMPANY

    Exhaust Gas Recirculation Coolant Return Pipe (3) @ Exhaust Gas Recirculation Coolant Return Pipe - Install

  40. Turbocharger Coolant Return Hose (2) @ Exhaust Gas Recirculation Coolant Return Pipe - Install
  41. Hose Clamp (1) - Engage [2x] - Hose Clamp Replacement Guidelines - Spring Type
  42. GM5485237Courtesy of GENERAL MOTORS COMPANY

    Thermostat Bypass Hose (1) - Install

  43. Engine Coolant Air Bleed Hose Stud (2) - Install and tighten - Fastener Specifications
  44. GM5635809Courtesy of GENERAL MOTORS COMPANY

    Exhaust Gas Recirculation Cooler Water Bypass Inlet Hose (2) @ Thermostat Bypass Hose - Install

  45. Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
  46. GM5150241Courtesy of GENERAL MOTORS COMPANY

    Air Cleaner Outlet Duct (2) - Install

  47. Air Cleaner Outlet Duct Clamp (1) - Tighten - Fastener Specifications
  48. GM5482184Courtesy of GENERAL MOTORS COMPANY

    Air Cleaner Lower Housing (1) - Install

  49. GM5482183Courtesy of GENERAL MOTORS COMPANY

    Air Cleaner Nut (1) - Install and tighten - Fastener Specifications

  50. GM5482182Courtesy of GENERAL MOTORS COMPANY

    Accessory Wiring Junction Block (2) - Install

  51. Engine Wiring Harness Fuse Block Bracket Bolt (1) - Install and tighten - Fastener Specifications
  52. GM5482181Courtesy of GENERAL MOTORS COMPANY

    Electrical Connector (1) @ Air Cleaner Lower Housing - Install

  53. Install all retainers to the air cleaner lower housing.
  54. GM5150254Courtesy of GENERAL MOTORS COMPANY

    Air Cleaner Upper Housing (2) - Install

  55. Air Cleaner Housing Cover Bolt (1) - Install and tighten [3x] - Fastener Specifications
  56. Connect the mass airflow sensor electrical connector.
  57. GM5654241Courtesy of GENERAL MOTORS COMPANY

    Intake Air Duct (2) - Install

  58. Intake Air Duct Retainer (1) - Install
  59. GM5617832Courtesy of GENERAL MOTORS COMPANY

    Intake Air Splash Shield (2) - Install

  60. Intake Air Baffle Retainer (1) - Install [9x]
  61. GM5541781Courtesy of GENERAL MOTORS COMPANY

    Hood Secondary Latch Release Handle (2) - Install

  62. Hood Latch Actuator Bolt (1) - Install and tighten [2x] - Fastener Specifications
  63. GM5612777Courtesy of GENERAL MOTORS COMPANY

    Throttle Body Gasket (3) - Install NEW

  64. Throttle Body (2) - Install
  65. Throttle Body Bolt (1) - Install and tighten [3x] - Fastener Specifications
  66. Connect the throttle body electrical connector.
  67. GM5211335Courtesy of GENERAL MOTORS COMPANY

    Charge Air Cooler Outlet Air Hose (2) - Install

  68. Charge Air Cooler Outlet Air Hose Clamp (1) - Tighten [2x] - Fastener Specifications
  69. GM5485774Courtesy of GENERAL MOTORS COMPANY

    Clip (2) @ Oil Level Indicator Tube - Install

  70. Oil Level Indicator Tube Stud (1) - Install and tighten - Fastener Specifications
  71. GM5485772Courtesy of GENERAL MOTORS COMPANY

    Engine Wiring Harness Bracket (2) - Install

  72. Engine Wiring Harness Bracket Nut (1) - Install and tighten [2x] - Fastener Specifications
  73. Front Wheelhouse Liner - Left Side - Install - Front Wheelhouse Liner Replacement
  74. Plenum Front Panel Outer Reinforcement - Install - Plenum Front Panel Outer Reinforcement Removal and Installation
  75. Oil Filler Cap - Remove
  76. GM5171779Courtesy of GENERAL MOTORS COMPANY

    Intake Manifold Cover (2) - Install

  77. Intake Manifold Cover Bolt (1) - Install and tighten - Fastener Specifications
  78. Oil Filler Cap - Install
  79. Fill the cooling system to the proper level. Cooling System Draining and Filling (Static LM2) , or Cooling System Draining and Filling (GE 47716 LM2)
  80. Start the engine and check for coolant leaks.
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