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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 421 (Engine Mechanical - 4.8L, 5.3L, & 6.0L (On-Vehicle)) >> Repair Instructions >> Intake Manifold Replacement >> Installation Procedure

Installation Procedure

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    Fig 1: View Of Intake Manifold Gasket
    GM492770Courtesy of GENERAL MOTORS CORP.
  1. Install new intake manifold gaskets (1) to the intake manifold.
    2. Fig 2: Intake Manifold & Bolts
    GM642285Courtesy of GENERAL MOTORS CORP.
  2. Install the intake manifold.
  3. Apply a 5 mm (0.20 in) band of threadlock GM U.S. P/N 12345382, Canada P/N 10953489, or equivalent to the threads of the intake manifold bolts.
    4. Fig 3: Identifying Intake Manifold Bolt Tightening Sequence
    GM63222Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  4. Install 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).

    5. Fig 4: View Of EVAP Purge Solenoid Bolt, Solenoid & Isolator
    GM389993Courtesy of GENERAL MOTORS CORP.
  5. Install the EVAP purge solenoid (3), isolator (1), and bolt (2) to the intake manifold.

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

    6. Fig 5: View Of EVAP Purge Solenoid Vent Tube
    GM372717Courtesy of GENERAL MOTORS CORP.
  6. Install the EVAP purge solenoid vent tube to the solenoid (1) and vapor pipe.
    7. Fig 6: Accelerator Control Cable Bracket & Bolts
    GM492765Courtesy of GENERAL MOTORS CORP.
  7. Install the accelerator control cable bracket (2) to the intake manifold.
  8. Install the accelerator control cable bracket bolts (1).

    Tighten:  Tighten the accelerator control cable bracket bolts to 10 N.m (89 lb in).

    9. Fig 7: MAP Sensor
    GM260159Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Lightly coat the MAP sensor seal with clean engine oil before installing.
  9. Install the MAP sensor (1) to the intake manifold.
    10. Fig 8: Breather Crossover Tube View
    GM647793Courtesy of GENERAL MOTORS CORP.
  10. Install the PCV hose with valve.
    11. Fig 9: Vacuum Brake Booster Hose At Intake Manifold Rear
    GM382483Courtesy of GENERAL MOTORS CORP.
  11. If equipped with vacuum assisted brakes, install the vacuum brake booster hose to the rear of the intake manifold.
    12. Fig 10: MAP Sensor, Knock Sensor & EGR Valve
    GM679527Courtesy of GENERAL MOTORS CORP.
  12. If equipped, position a new EGR pipe gasket on the exhaust manifold.
  13. If equipped, install the EGR pipe with valve.
  14. If equipped, install the following EGR pipe bolts until snug:
    • Intake manifold (1)
    • Cylinder head (2)
    • Exhaust manifold (3)
  15. If equipped, tighten the EGR pipe bolts.

    Tighten: 

    • Tighten the EGR valve pipe-to-intake manifold bolts to 10 N.m (89 lb in).
    • Tighten the EGR valve pipe-to-cylinder head bolts to 50 N.m (37 lb ft).
    • Tighten the EGR valve pipe-to-exhaust manifold bolts to 30 N.m (22 lb ft).

  16. Route the electrical harness into position over the engine.
    17. Fig 11: View Of MAP Sensor & Knock Sensor Electrical Connectors
    GM679510Courtesy of GENERAL MOTORS CORP.
  17. Connect the knock sensor harness electrical connector to the intake manifold.
  18. Connect the following electrical connectors.
    • MAP sensor (1)
    • Knock sensor (2)
    • EGR valve, if equipped
  19. Install the fuel injectors. Refer to FUEL INJECTORS .
  20. Install the throttle body. Refer to THROTTLE BODY .
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