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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> Engine Mechanical >> Engine Mechanical - 4.3L >> Repair Instructions >> On-Vehicle Repair Instructions >> Intake Manifold Replacement - Lower >> Installation Procedure

Installation Procedure

  1. Install the lower intake manifold. Refer to INTAKE MANIFOLD REPLACEMENT - LOWER  .
    Fig 1: Installing Lower Intake Manifold Bolt
    G01643663Courtesy of GENERAL MOTORS CORP.
  2. Reposition the power steering pump mounting bracket.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  3. Install the power steering pump mounting bracket three bolts and the nut.

    Tighten 

    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).

  4. Install A/C compressor side brace and bolts.

    Tighten 

    1. 4.1. Tighten the A/C compressor side brace bolt to 25 N.m (18 lb ft).
    2. 4.2. Tighten the side brace bolt to the generator bracket to 25 N.m (18 lb ft).
  5. Install the oil filler tube and bolt.

    Tighten 

    Tighten the oil filler tube bolt to 25 N.m (18 lb ft).

  6. Install the drive belt. Refer to DRIVE BELT REPLACEMENT  .
  7. Install the EVAP canister purge valve. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
  8. Install the fuel supply and return pipes to the rear of the intake manifold. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.

    Important:  In order to install the distributor for the correct engine timing, position the engine to number one cylinder top dead center.

  9. Remove the spark plug for number one cylinder.
  10. Rotate the crankshaft until number one cylinder is in the compression stroke.
  11. Align the 2 reference marks on the crankshaft balancer (1, 4) with the 2 alignment marks (2, 3) on the front cover.
    Fig 2: Aligning Crankshaft Balancer Reference Marks With Front Cover Alignment Marks
    G01643664Courtesy of GENERAL MOTORS CORP.
  12. Install the spark plug. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
  13. Install the distributor. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
  14. Install the ICM. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
  15. Install the accelerator control cable bracket, studs, and nuts to the intake manifold and the throttle body.
    Fig 3: Installing Accelerator Control Cable Bracket, Studs And Nuts To Intake Manifold
    G01643665Courtesy of GENERAL MOTORS CORP.

    Tighten 

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

  16. Install the vacuum hose to the intake manifold.
    Fig 4: Installing Vacuum Hose To Intake Manifold
    G01643666Courtesy of GENERAL MOTORS CORP.
  17. Install the transmission fluid fill tube and bolt to the accelerator control cable bracket.
    Fig 5: Installing Transmission Fluid Fill Tube And Bolt To Accelerator Control Cable Bracket
    G01643667Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the transmission fluid fill tube bolt 6 N.m (53 lb in).

  18. Install the water pump inlet hose to the intake manifold.
    Fig 6: Installing Water Pump Inlet Hose To Intake Manifold
    G01643668Courtesy of GENERAL MOTORS CORP.
  19. Install the heater hoses. Refer to HEATER HOSE REPLACEMENT - INLET in Heating, Ventilation and Air Conditioning.
  20. Install the radiator inlet hose to the water outlet. Refer to RADIATOR HOSE REPLACEMENT - INLET in Engine Cooling.
  21. Position the engine wiring harness.
  22. Connect the following electrical connectors:
    • The A/C compressor clutch, if equipped (1)
    • The A/C high pressure cutoff switch, if equipped (5)
    • The throttle position (TP) sensor (2)
    • The idle air control (IAC) motor (3)
    • The fuel meter body assembly connector (4)
    Fig 7: Connecting Electrical Connectors
    G01643669Courtesy of GENERAL MOTORS CORP.
  23. Connect the following electrical connectors:
    • The manifold absolute pressure (MAP) sensor (4)
    • The EVAP canister purge solenoid valve (1)
  24. Install the ground wire and the nut to the water outlet stud.

    Tighten 

    Tighten the ground wire nut to 19 N.m (14 lb ft).

    Fig 8: Connecting Electrical Connectors
    G01643670Courtesy of GENERAL MOTORS CORP.
  25. Install the nut and the engine wiring harness bracket to the stud for the EVAP canister purge valve.
    Fig 9: Installing Nut And Engine Wiring Harness Bracket To EVAP Canister Purge Valve Stud
    G01643671Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the engine wiring harness bracket nut to 8 N.m (71 lb in).

  26. Install the nut and the engine wiring harness bracket to the intake manifold stud.

    Tighten 

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

  27. Install the nut and the A/C hose bracket to the intake manifold stud, if equipped.
    Fig 10: Installing A/C Hose Bracket To Intake Manifold Stud
    G01643672Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the A/C hose bracket nut to 5 N.m (44 lb in).

  28. Install the PCV valve hose assembly to the intake manifold and the valve rocker arm cover.
    Fig 11: Installing PCV Valve Hose Assembly To Intake Manifold And Valve Rocker Arm Cover
    G01643673Courtesy of GENERAL MOTORS CORP.
  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 ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
  31. Refill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
  32. Install air cleaner outlet duct to the throttle body. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
  33. Install the air cleaner assembly. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
  34. Connect the battery negative cable. Refer to BATTERY REPLACEMENT in Battery.
  35. Install the engine cover. Refer to ENGINE COVER REPLACEMENT in Interior Trim.
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