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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1029 (Engine Mechanical - 4.8L, 5.3L & 6.0L (Repair Instructions - 3 Of 3)) >> Repair Instructions (Off-Vehicle Repair Instructions Part 3) >> Intake Manifold Installation

Intake Manifold Installation

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    IMPORTANT:
    • The intake manifold, throttle body, fuel injection rail and fuel injectors may be removed as an assembly. If not servicing the individual components, install the intake manifold as a complete assembly.
    • DO NOT use the old intake manifold gaskets again. Install NEW intake manifold-to-cylinder head gaskets.
  1. Install NEW intake manifold-to-cylinder head gaskets (514).
    2. Fig 1: View Of Intake Manifold-To-Cylinder Head Gasket
    GM1277097Courtesy of GENERAL MOTORS CORP.
  2. Install the intake manifold.
    3. Fig 2: View Of Intake Manifold & Bolts
    GM1201541Courtesy of GENERAL MOTORS CORP.
  3. Apply a 5 mm (0.20 in) band of threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the intake manifold bolts. Refer to Sealers, Adhesives, and Lubricants .
    4. NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Install the intake manifold bolts.

    Tighten: 

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

    5. Fig 3: Identifying Intake Manifold Bolt Tightening Sequence
    GM63222Courtesy of GENERAL MOTORS CORP.
  5. Install the manifold absolute pressure (MAP) sensor (714), if previously removed.

    The electrical connector end of the sensor should be facing the front of the engine.

    6. Fig 4: View Of MAP Sensor
    GM1277093Courtesy of GENERAL MOTORS CORP.
    Fig 5: View Of PCV Hose
    GM1201537Courtesy of GENERAL MOTORS CORP.
  6. Install the positive crankcase ventilation (PCV) dirty air hose.
  7. Install the engine coolant air bleed hose and clamp onto the throttle body.
  8. Install the evaporative emission (EVAP) purge solenoid (708), bolt (710), and isolator (709).

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

    9. Fig 6: View Of EVAP Purge Solenoid, Bolt & Isolator
    GM1277094Courtesy of GENERAL MOTORS CORP.
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