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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> Engine Mechanical >> Engine Mechanical - 4.3L >> Repair Instructions >> Off-Vehicle Repair Instructions >> Intake Manifold Assembly (LU3)

Intake Manifold Assembly (LU3)

  1. If reusing the fastener, apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the threads of the fuel meter body bracket bolt.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  2. Install the fuel meter body bracket and bolt.

    Tighten 

    Tighten the fuel meter bracket bolt to 10 N.m (89 lb in).

    Important:  All injector lines must face forward as the fuel meter body is snapped into the bracket. Also, the number three fuel tube must be positioned behind the number one fuel tube to eliminate interference with the upper intake manifold when installed.

  3. Install the fuel meter body into the fuel meter body bracket.
    Fig 1: Installing Fuel Meter Body
    G01644008Courtesy of GENERAL MOTORS CORP.
  4. Install the 6 injections into the proper lower intake manifold bores in proper sequence (3, 5, 1, 2, 4, 6).
  5. Inspect the injectors in order to ensure that they are firmly seated and locked in the lower intake manifold bores.
  6. Ensure that the electrical connections of the injectors are positioned so that they do not interfere with each other, and are pointing towards the center of the intake manifold. Rotate the electrical connector inboard if necessary. Also, ensure there is not tension on the injector wires.
  7. Install a NEW upper intake manifold to lower intake manifold gasket into the groove of the upper intake manifold.
  8. Install the upper intake manifold onto the lower intake manifold.
    Fig 2: Installing Upper Intake Manifold Onto Lower Intake Manifold
    G01644009Courtesy of GENERAL MOTORS CORP.
  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 studs.
  10. Install the upper intake manifold attaching studs.

    Tighten 

    1. 10.1. Tighten the upper intake manifold attaching studs on the first pass to 5 N.m (44 lb in).
    2. 10.2. Tighten the upper intake manifold attaching studs on the final pass to 9 N.m (80 lb in).
  11. If reusing the fasteners, apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the threads of the evaporative emission (EVAP) canister purge solenoid valve studs.
  12. Install the EVAP canister purge solenoid valve and studs.
    Fig 3: Installing EVAP Canister Purge Solenoid Valve And Studs
    G01644010Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the EVAP canister purge solenoid valve studs to 10 N.m (89 lb in).

  13. Install the engine wiring harness bracket and nut.

    Tighten 

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

  14. Install the NEW fuel seals (8), black O-rings, into the fuel meter body.
    Fig 4: Installing New Fuel Seals
    G01644011Courtesy of GENERAL MOTORS CORP.
  15. Install the NEW spacer rings (7), flat washers, into the fuel meter body.
  16. Install the NEW fuel seals (6), yellow O-rings, into the fuel meter body.
  17. Install the NEW fuel seal retainers (5) into the fuel meter body.
  18. Install the fuel pipe (3) into the fuel meter body.
  19. Install the fuel pipe retainer bracket (2) onto the fuel pipe.
  20. Install the fuel pipe retainer bracket nuts (1).
  21. If reusing the fastener, apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the threads of the fuel pipe bolt.
  22. Install the fuel pipe bolt (4).

    Tighten 

    1. 22.1. Tighten the fuel pipe bracket nuts to 3 N.m (27 lb in).
    2. 22.2. Tighten the fuel pipe bolt to 6 N.m 53 lb in).
  23. Install a NEW manifold absolute pressure (MAP) sensor seal onto the MAP sensor.
  24. Apply a small amount, approximately 1 drop, of clean engine oil to the MAP sensor seal.
  25. Install the MAP sensor into the upper intake manifold.
    Fig 5: Installing MAP Sensor
    G01644012Courtesy of GENERAL MOTORS CORP.
  26. Install the ignition coil and studs.
    Fig 6: Installing Ignition Coil And Studs
    G01644013Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the ignition coil studs to 12 N.m (106 lb in).

  27. If reusing the engine coolant temperature (ECT) sensor plug (1) or the ECT sensor (2), if equipped, apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the threads of the ECT sensor plug (1) or the ECT sensor (2).
    Fig 7: Tightening ECT Sensor
    G01644014Courtesy of GENERAL MOTORS CORP.
  28. Install the ECT sensor or plug, if equipped, into the front of the lower intake manifold.

    Tighten 

    Tighten the ECT sensor or plug to 20 N.m (15 lb ft).

  29. Install the engine coolant thermostat.
  30. Install the water outlet (1 or 2).
    Fig 8: Installing Water Outlet
    G01644015Courtesy of GENERAL MOTORS CORP.
  31. Install the water outlet studs.

    Tighten 

    Tighten the water outlet studs to 25 N.m (18 lb ft).

  32. Install a NEW throttle body gasket into the groove in the upper intake manifold.
    Fig 9: Installing Throttle Body
    G01644016Courtesy of GENERAL MOTORS CORP.
  33. Install the throttle body into the upper intake manifold.
  34. If reusing the fasteners, apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the threads of the throttle body attaching studs.
  35. Install the throttle body attaching studs.
    Fig 10: Tightening Throttle Body Attaching Studs
    G01644017Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the throttle body attaching studs to 9 N.m (80 lb in).

  36. Install the accelerator control cable bracket, the studs, and the nuts.

    Tighten 

    Fig 11: Installing Accelerator Control Cable Bracket, Studs And Nuts
    G01644018Courtesy of GENERAL MOTORS CORP.
    1. 36.1. Tighten the accelerator control cable bracket stud to the intake manifold to 6 N.m (53 lb in).
    2. 36.2. Tighten the accelerator control cable bracket nuts to 12 N.m (106 lb in).
    3. 36.3. Tighten the accelerator control cable bracket stud to the throttle body to 12 N.m (106 lb in).
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