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Home >> GMC >> 2003 >> Yukon Denali >> Repair and Diagnosis >> External Pages >> Different car >> Section 497 (Engine Mechanical (Repair Instructions -- 1 Of 3) -- 4.8L, 5.3L & 6.0L) >> Repair Instructions (On-Vehicle & Off-Vehicle - Part 1) >> On-Vehicle Repair Instructions >> Intake Manifold Replacement >> Installation Procedure

Installation Procedure

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  1. Install NEW intake manifold gaskets (1) to the intake manifold.
    2. Fig 1: View Of Intake Manifold Gasket
    GM492770Courtesy of GENERAL MOTORS CORP.
  2. Install the intake manifold.
  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.
    4. Fig 2: View Of Intake Manifold & Bolts
    GM1201541Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Tighten the intake manifold bolts.

    Tighten: 

    1. Tighten the bolts a first pass in sequence to 5 N.m (44 lb in).
    2. Tighten the bolts a 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 EVAP purge solenoid (3), isolator (1), and bolt (2) to the intake manifold.

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

    6. Fig 4: View Of EVAP Purge Solenoid Bolt, Solenoid & Isolator
    GM389993Courtesy of GENERAL MOTORS CORP.
  6. Install the EVAP purge solenoid vent tube to the solenoid (1) and vapor pipe (2).
    7. Fig 5: View Of EVAP Tube To Solenoid & Vapor Pipe
    GM1285743Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Lightly coat the MAP sensor seal with clean engine oil before installing.
  7. Install the MAP sensor (1) to the intake manifold.
    8. Fig 6: View Of MAP Sensor
    GM1201538Courtesy of GENERAL MOTORS CORP.
  8. Install the PCV hose.
    9. Fig 7: View Of PCV Hose
    GM1201537Courtesy of GENERAL MOTORS CORP.
  9. If equipped with vacuum assisted brakes, install the vacuum brake booster hose to the rear of the intake manifold.
    10. Fig 8: View Of Vacuum Brake Booster Hose To Intake Manifold Rear (5.3L Engine w/RPO HP2)
    GM1236362Courtesy of GENERAL MOTORS CORP.
  10. Route the electrical harness into position over the engine.
  11. Connect the knock sensor harness electrical connector to the intake manifold.
  12. Connect the following electrical connectors.
    • MAP sensor (1)
    • Knock sensor (2)
    13. Fig 9: View Of MAP Sensor & Knock Sensor Electrical Connectors
    GM679510Courtesy of GENERAL MOTORS CORP.
  13. Install the fuel injectors. Refer to Fuel Injector Replacement in Engine Controls - 4.8L, 5.3L, and 6.0L.
  14. Install the throttle body. Refer to Throttle Body Assembly Replacement in Engine Controls - 4.8L, 5.3L, and 6.0L.
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