Removal & Installation (C3500 HD)
WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2002 GMC Savana Special, 2002 GMC Savana Camper Special, 2002 GMC Savana, 2002 GMC C3500 HD, and 2002 Chevrolet RV Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
- Disconnect both the battery negative cables from the batteries. Remove the upper intake manifold from the lower intake manifold. See UPPER INTAKE MANIFOLD . Remove the fuel filter from the lower intake manifold and position to the side.
- Remove the glow plug relay from the lower intake manifold. Remove the nuts retaining the heater hose bracket. Remove the heater hoses and bracket. Remove the ground straps from the right rear corner of the lower intake manifold. Disconnect the engine wiring harness (if needed) and secure out of the way.
- Remove the lower intake manifold bolts from the cylinder head. Remove the lower intake manifold and the gasket from the cylinder heads. Clean and check the sealing surfaces of the cylinder head and the engine block.
- Install the intake manifold and gaskets. Install the intake manifold bolts/studs and fuel line clips. Use Teflon sealer to seal the four bolts, numbers 9, 11, 13, and 15 that are exposed to the crankcase. See Fig 1. Apply Threadlocker (GM 12345493 or Canadian GM 10953488) to the threads of the bolts and the studs that are not numbered 9, 11, 13, or 15. Tighten the intake manifold fasteners in sequence. See Fig 1. To complete installation, reverse removal procedure. Tighten fasteners properly. See TORQUE SPECIFICATIONS .