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Home >> GMC >> 2006 >> Sierra 1500 HD, 4WD >> Repair and Diagnosis >> External Pages >> Different car >> Section 144 (Engine Mechanical - 4.3L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Intake Manifold Replacement - Lower >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2003 GMC Savana and 2003 Chevrolet Chevy Express. However, it is still accessible from the selected car via links, so may be relevant.
  1. Apply a 4.0 mm (0.157 in) patch of adhesive GM P/N 12346141 (Canadian P/N 10953433) or equivalent to the cylinder head side of the lower intake manifold gasket at each end.

    Important:  The lower intake manifold gasket must be installed while the adhesive is still wet to the touch.

  2. Install the lower intake manifold gasket onto the cylinder head.

    Use the gasket locator pins in order to properly seat the lower intake manifold gasket on the cylinder head.

    Fig 1: Applying Adhesive To Cylinder Head Side Of Lower Intake Manifold Gasket
    G02077723Courtesy of GENERAL MOTORS CORP.

    Important:  The lower intake manifold must be installed and the fasteners tightened while the adhesive is still wet to the touch.

  3. Apply a 5 mm (0.197 in) bead of adhesive GM P/N 12346141 (Canadian P/N 10953433) or equivalent to the front top of the engine block.
  4. Extend the adhesive bead 13 mm (0.50 in) onto each lower intake manifold gasket.
    Fig 2: Applying Adhesive To Front Top Of Engine Block
    G02077724Courtesy of GENERAL MOTORS CORP.
  5. Apply a 5 mm (0.197 in) bead of adhesive GM P/N 12346141 (Canadian P/N 10953433) or equivalent to the rear top of the engine block.
  6. Extend the adhesive bead 13 mm (0.50 in) onto each lower intake manifold gasket.
    Fig 3: Applying Adhesive To Rear Top Of Engine Block
    G02077725Courtesy of GENERAL MOTORS CORP.
  7. Install the lower intake manifold onto the engine block.
  8. If reusing the fasteners, apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the lower intake manifold bolts.
  9. Install the lower intake manifold bolts.
    Fig 4: Installing Lower Intake Manifold & Bolts
    G02077726Courtesy of GENERAL MOTORS CORP.
    CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
  10. Tighten the lower intake manifold bolts.

    Tighten 

    1. Tighten the bolts on the first pass in sequence (1-8) to 3 N.m (27 lb in).
    2. Tighten the bolts on the second pass in sequence (1-8) to 12 N.m (106 lb in).
    3. Tighten the bolts on the final pass in sequence (1-8) to 15 N.m (11 lb ft).
      Fig 5: Tightening Lower Intake Manifold Bolts
      G02077727Courtesy of GENERAL MOTORS CORP.
  11. Position the power steering pump mounting bracket.
  12. Install the power steering pump mounting bracket, 3 bolts and the nut.

    Tighten 

    • Tighten the power steering pump mounting bracket bolts and the nut to 41 N.m (30 lb ft).
    • Tighten the power steering pump rear bracket nut to 41 N.m (30 lb ft).
    • Tighten the power steering pump mounting bracket bolts and the nut and the power steering pump rear bracket nut to 41 N.m (30 lb ft).
  13. Install the drive belt. Refer to Drive Belt Replacement .
  14. Install the A/C compressor discharge hose from the vehicle. Refer to DISCHARGE HOSE REPLACEMENT .
  15. Install the A/C compressor suction hose from the vehicle. Refer to SUCTION HOSE REPLACEMENT .
    Fig 6: Installing Power Steering Pump Mounting Bracket
    G02077728Courtesy of GENERAL MOTORS CORP.

    Important:  In order to install the distributor for the correct engine timing, position the engine to number one cylinder top dead center (TDC).

  16. Remove the spark plug for number one cylinder.
  17. Rotate the crankshaft until number one cylinder is in the compression stroke.
  18. Align the 2 reference marks on the crankshaft balancer (1) and (4) with the 2 alignment marks (2) and (3) on the front cover.
  19. Install the spark plug. Refer to SPARK PLUGS .
  20. Install the distributor. Refer to DISTRIBUTOR .
    Fig 7: Aligning Reference Marks On Crankshaft Balancer & Front Cover
    G02077729Courtesy of GENERAL MOTORS CORP.
  21. Install the upper intake. Refer to Intake Manifold Replacement - Upper .
  22. Install the accelerator control cable bracket, studs, and nuts to the intake manifold and the throttle body.

    Tighten 

    Tighten the accelerator control cable bracket nuts and studs to 12 N.m (106 lb in).

    Fig 8: Installing Accelerator Control Cable Bracket Nuts & Studs
    G02077730Courtesy of GENERAL MOTORS CORP.
  23. Install the water pump inlet hose to the intake manifold.
  24. Install the heater hoses. Refer to HEATER HOSE REPLACEMENT - INLET and HEATER HOSE REPLACEMENT - OUTLET .
  25. Install the radiator inlet hose to the water outlet. Refer to RADIATOR HOSE REPLACEMENT - INLET .
    Fig 9: Installing Water Pump Inlet Hose
    G02077731Courtesy of GENERAL MOTORS CORP.
  26. Connect the following electrical connectors:
    • The fuel meter body assembly connector (1)
    • The evaporative emission (EVAP) canister purge solenoid valve (2)
    • The manifold absolute pressure (MAP) sensor (3)
    • The A/C high pressure switch (4), if equipped.
      Fig 10: Connecting Connectors
      G02077732Courtesy of GENERAL MOTORS CORP.
  27. Connect the following electrical connectors:
    • The A/C compressor clutch (1), if equipped
    • The EGR valve (2)
    • The ECT sensor (3)
  28. Install the ground wire (4) and the nut to the water outlet stud.

    Tighten 

    Tighten the ground wire nut to 10 N.m (88 lb in).

    29. Fig 11: Connecting A/C Compressor Clutch, EGR Valve, ECT Sensor & Ground Wire
    G02077733Courtesy of GENERAL MOTORS CORP.
  29. Install the cruise control cable, if equipped to the throttle shaft and the accelerator control cable bracket. Refer to Cruise Control Cable Replacement in Cruise Control .
  30. Install the accelerator control cable to the throttle shaft and the accelerator control cable bracket.
  31. Refill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM .
  32. Install the air cleaner assembly.
  33. Connect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure .
  34. Install the engine cover. Refer to Engine Cover Replacement in Interior Trim .
    Fig 12: Installing Air Cleaner Outlet Duct & Retaining Nut
    G02077734Courtesy of GENERAL MOTORS CORP.
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