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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 - Upper >> Installation Procedure

Installation Procedure

  1. Install the throttle body, if removed. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
  2. Install the MAP sensor, if removed. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
  3. Install the PCV valve cover, if removed, using the following procedure:
    1. 3.1 Install a NEW seal (O-ring) on the PCV valve cover.
    2. 3.2 Lubricate the seal with clean engine oil.
    3. 3.3 Install the PCV valve cover in the upper intake manifold.
    4. 3.4 Turn and lock the PCV valve cover in position.
    Fig 1: Installing PCV Valve In Upper Intake Manifold
    G01643641Courtesy of GENERAL MOTORS CORP.
  4. Install a NEW seal on the fuel meter body assembly.
    Fig 2: Installing New Seal On Fuel Meter Body Assembly
    G01643642Courtesy of GENERAL MOTORS CORP.
  5. Lubricate the seal with clean engine oil.
  6. Install a NEW upper intake manifold to lower intake manifold gasket in the groove of the upper intake manifold.
    Fig 3: Installing New Upper Intake Manifold To Lower Intake Manifold Gasket
    G01643643Courtesy of GENERAL MOTORS CORP.
  7. Install the upper intake manifold onto the lower intake manifold.
    Fig 4: Installing Upper Intake Manifold Onto Lower Intake Manifold
    G01643644Courtesy of GENERAL MOTORS CORP.
  8. If reusing the fasteners, apply threadlock GM P/N 12345382 or equivalent to the threads of the upper intake manifold attaching bolts.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  9. Install the upper intake manifold attaching studs.

    Tighten 

    1. 9.1 Tighten the upper intake manifold attaching studs on the first pass to 5 N.m (44 lb in).
    2. 9.2 Tighten the upper intake manifold attaching studs on the final pass to 9 N.m (80 lb in).
  10. Install the fuel lines to the fuel meter body assembly. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
  11. Install the EVAP canister purge valve. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
  12. Install the accelerator control cable bracket, studs, and nuts to the intake manifold and the throttle body.
    Fig 5: Installing Accelerator Control Cable Bracket, Studs And Nuts
    G01643645Courtesy of GENERAL MOTORS CORP.

    Tighten 

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

  13. Connect the vacuum hose to the intake manifold.
    Fig 6: Connecting Vacuum Hose To Intake Manifold
    G01643646Courtesy of GENERAL MOTORS CORP.
  14. Install the transmission fluid fill tube and bolt to the accelerator control cable bracket.
    Fig 7: Installing Transmission Fluid Fill Tube And Bolt To Accelerator Control Cable Bracke
    G01643647Courtesy of GENERAL MOTORS CORP.

    Tighten 

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

  15. Position the engine wiring harness.
  16. 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 8: Connecting Electrical Connectors
    G01643648Courtesy of GENERAL MOTORS CORP.
  17. Connect the following electrical connectors:
    • The manifold absolute pressure (MAP) sensor (4)
    • The EVAP canister purge solenoid valve (1)
      Fig 9: Connecting MAP Sensor & EVAP Canister Purge Solenoid Valve
      G01643649Courtesy of GENERAL MOTORS CORP.
  18. Install the engine wiring harness bracket and nut to the intake manifold stud.

    Tighten 

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

  19. Install the A/C hose bracket and nut, if equipped to the intake manifold stud.
    Fig 10: Installing A/C Hose Bracket & Nut
    G01643650Courtesy of GENERAL MOTORS CORP.

    Tighten 

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

  20. Install the engine wiring harness bracket and the nut onto the stud at the EVAP canister purge solenoid valve.
    Fig 11: Installing Engine Wiring Harness Bracket
    G01643651Courtesy of GENERAL MOTORS CORP.

    Tighten 

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

  21. Connect the PCV valve hose assembly to the intake manifold and the valve rocker arm cover.
    Fig 12: Connecting PCV Valve Hose Assembly To Intake Manifold And Valve Rocker Arm Cover
    G01643652Courtesy of GENERAL MOTORS CORP.
  22. 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.
  23. Install the accelerator control cable to the throttle shaft and the accelerator control cable bracket. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
  24. Install the air cleaner outlet duct to the throttle body assembly. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
  25. Install the engine cover. Refer to ENGINE COVER REPLACEMENT in Interior Trim.
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