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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1302 (Engine Mechanical (Repair Instructions 1 Of 3) - 5.7L) >> Repair Instructions (On-Vehicle & Off-Vehicle - Part 1 >> On-Vehicle Repair Instructions >> Intake Manifold Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
IMPORTANT: DO NOT reuse the intake manifold gaskets. Install NEW intake manifold gaskets.
    Fig 1: Intake Manifold Gaskets
    GM490579Courtesy of GENERAL MOTORS CORP.
  1. Install NEW intake manifold gaskets (1) to the manifold.
    2. Fig 2: Intake Manifold
    GM639836Courtesy of GENERAL MOTORS CORP.
  2. Install intake manifold.
  3. Position the intake manifold forward.
    4. Fig 3: MAP Sensor Vacuum Hose & MAP Sensor Electrical Connector
    GM651870Courtesy of GENERAL MOTORS CORP.
  4. Connect the MAP sensor vacuum hose.
  5. Connect the MAP sensor (3) electrical connector.
  6. Position the intake manifold into place.
    7. Fig 4: Intake Manifold Bolts & Fuel Rail Stop Bracket
    GM490927Courtesy of GENERAL MOTORS CORP.
    CAUTION: The fuel rail stop bracket must be installed onto the engine assembly. The stop bracket serves as a protective shield for the fuel rail in the event of a vehicle frontal crash. If the fuel rail stop bracket is not installed and the vehicle is involved in a frontal crash, fuel could be sprayed possibly causing a fire and personal injury from burns.
  7. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent to the threads of the intake manifold bolts (1).
  8. Install the fuel rail stop bracket (2).
  9. Install the intake manifold bolts (1).
    10. Fig 5: Identifying Intake Manifold Bolt Tightening Sequence
    GM63222Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  10. Tighten the intake manifold bolts.

    Tighten: 

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

    11. Fig 6: PCV Valve Hose
    GM668802Courtesy of GENERAL MOTORS CORP.
  11. If equipped with the RPO LS6 engine, install the PCV valve hose (1) to the valley cover and intake manifold.
    12. Fig 7: Right Rocker Arm Cover & PCV Valve Pipe
    GM379367Courtesy of GENERAL MOTORS CORP.
  12. If equipped with the RPO LS1 engine, install the PCV valve pipe to the right valve rocker arm cover and intake manifold.
  13. Install the PCV pipe strap nut.

    Tighten:  Tighten the PCV pipe strap nut to 12 N.m (106 lb in).

    14. Fig 8: Left Rocker Arm Cover & PCV Valve Pipe
    GM379366Courtesy of GENERAL MOTORS CORP.
  14. If equipped with the RPO LS1 engine, install the PCV valve pipe to the left rocker arm cover.
    15. Fig 9: TP Sensor Harness Clip & PCV Tube
    GM379368Courtesy of GENERAL MOTORS CORP.
  15. Install the PCV tube to the right rocker arm cover.
  16. Install the TP sensor harness clip to the PCV tube.
    17. Fig 10: Knock Sensor Wire Harness Clip & Fuel Rail Stop Bracket
    GM639835Courtesy of GENERAL MOTORS CORP.
  17. Install the knock sensor wire harness (1) to the fuel rail stop bracket (2).
    18. Fig 11: Identifying Vacuum Booster Hose
    GM63936Courtesy of GENERAL MOTORS CORP.
  18. Connect the power brake booster vacuum hose to the booster.
    19. Fig 12: EVAP Canister Purge Solenoid Valve & Bracket
    GM419407Courtesy of GENERAL MOTORS CORP.
  19. Position the intake manifold branches of the wiring harness.
  20. Connect the harness clips at the fuel rails.
  21. Install the EVAP canister purge solenoid valve from the bracket.
    22. Fig 13: Electrical Connectors
    GM651871Courtesy of GENERAL MOTORS CORP.
  22. Connect the ETC electrical connector (3).
  23. Connect the EVAP canister purge solenoid valve electrical connector (2).
  24. Connect all the fuel injector electrical connectors (1).
    25. Fig 14: Throttle Body Heater Outlet Hose & Clamp
    GM672639Courtesy of GENERAL MOTORS CORP.
  25. Install the throttle body heater outlet hose.
  26. Install the throttle body heater outlet hose to the throttle body.
  27. Position the throttle body heater outlet hose clamp at the throttle body.
  28. Install the coolant air bleed hose. Refer to Coolant Air Bleed Hose Replacement in Engine Cooling.
    29. Fig 15: TP Sensor Electrical Connector
    GM51808Courtesy of GENERAL MOTORS CORP.
  29. Connect the TP sensor electrical connector.
    30. Fig 16: Fuel Feed Pipe
    GM651865Courtesy of GENERAL MOTORS CORP.
  30. Install the EVAP canister purge tube.
  31. Connect the EVAP canister purge tube to the fuel feed pipe.
  32. Connect the EVAP canister purge tube to the EVAP canister purge solenoid valve.
    33. Fig 17: EVAP Canister Purge Tube
    GM651868Courtesy of GENERAL MOTORS CORP.
  33. Install the EVAP canister purge tube.
  34. Connect the EVAP canister purge tube to the EVAP canister purge solenoid valve.
  35. Connect the EVAP canister purge tube to the intake manifold.
  36. Install the fuel feed hose. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls - 5.7 L.
    37. Fig 18: Left Fuel Rail Cover
    GM651873Courtesy of GENERAL MOTORS CORP.
  37. Install the left fuel rail cover.
    38. Fig 19: Right Fuel Injection Rail Cover
    GM651872Courtesy of GENERAL MOTORS CORP.
  38. Install the right fuel rail cover.
  39. If replacing the intake manifold, perform the following:
  40. Fill the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling.
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