LEMON Manuals: Even more car manuals for everyone
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 - Upper >> 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. Install the throttle body, if removed. Refer to THROTTLE BODY .
  2. Install the MAP sensor, if removed. Refer to MANIFOLD ABSOLUTE PRESSURE SENSOR .
  3. Install the PCV valve cover, if removed, using the following procedure:
    1. Install a NEW seal (O-ring) on the PCV valve cover.
    2. Lubricate the seal with clean engine oil.
    3. Install the PCV valve cover in the upper intake manifold.
    4. Turn and lock the PCV valve cover in position.
      Fig 1: Installing PCV Valve Cover
      G02077706Courtesy of GENERAL MOTORS CORP.
  4. Install the power brake booster vacuum tube fitting, if removed, using the following procedure:
    1. Install a NEW seal (O-ring) on the power brake booster vacuum tube fitting.
    2. Lubricate the seal with clean engine oil.
    3. Install the power brake booster vacuum tube fitting in the upper intake manifold.
    4. Turn and lock the power brake booster vacuum tube fitting in position.
      Fig 2: Installing Power Brake Booster Vacuum Tube Fitting
      G02077707Courtesy of GENERAL MOTORS CORP.
  5. Install a NEW seal on the fuel meter body assembly.
  6. Lubricate the seal with clean engine oil.
    Fig 3: Installing Seal On Fuel Meter Body Assembly
    G02077708Courtesy of GENERAL MOTORS CORP.
  7. Install a NEW upper intake manifold to lower intake manifold gasket in the groove of the upper intake manifold.
    Fig 4: Installing Upper Intake Manifold To Lower Intake Manifold Gasket
    G02077709Courtesy of GENERAL MOTORS CORP.
  8. Install the upper intake manifold onto the lower intake manifold.
  9. If reusing the fasteners, apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the upper intake manifold attaching bolts.
    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. Install the upper intake manifold attaching studs.

    Tighten 

    1. Tighten the upper intake manifold attaching studs on the first pass to 5 N.m (44 lb in).
    2. Tighten the upper intake manifold attaching studs on the final pass to 9 N.m (80 lb in).
    Fig 5: Installing Upper Intake Manifold & Studs
    G02077710Courtesy of GENERAL MOTORS CORP.
  11. Install the fuel lines to the fuel meter body assembly.
  12. Install the distributor cap. Refer to DISTRIBUTOR .
  13. Install the ignition control module. Refer to IGNITION CONTROL MODULE .
  14. Install the EVAP canister purge solenoid valve. Refer to EVAP CANISTER PURGE VALVE .
  15. 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 6: Installing Accelerator Control Cable Bracket, Studs & Nuts
    G02077711Courtesy of GENERAL MOTORS CORP.
  16. Connect the A/C vacuum hose to the intake manifold.
  17. Install the power brake booster vacuum hose bracket and nut to the intake manifold stud.

    Tighten 

    Tighten the power brake booster vacuum hose bracket nut to 11 N.m (97 lb in).

  18. Connect the power brake booster vacuum hose to the intake manifold.
    Fig 7: Connecting Vacuum Hoses & Installing Bracket
    G02077712Courtesy of GENERAL MOTORS CORP.
  19. Install the bracket for the engine wiring harness on the lower intake manifold stud.
  20. Install the engine wiring harness bracket nut.

    Tighten 

    Tighten the engine wiring harness bracket nut to 12 N.m (106 lb in).

    Fig 8: Installing Engine Wiring Harness Bracket
    G02077713Courtesy of GENERAL MOTORS CORP.
  21. Connect the following electrical connectors:
    • The fuel meter body assembly connector (1)
    • The EVAP canister purge solenoid valve (2)
    • The manifold absolute pressure (MAP) sensor (3)
      Fig 9: Connecting Fuel Meter Body Assembly Connector, EVAP Canister Purge Solenoid Valve & MAP Sensor
      G02077714Courtesy of GENERAL MOTORS CORP.
  22. Connect the following electrical connectors:
    • The throttle position (TP) sensor (1)
    • The idle air control (IAC) motor (2)
    • The engine coolant temperature (ECT) gage sensor (3)
    • The A/C high pressure switch (4), if equipped
      Fig 10: Installing TP Senor, IAC Motor, ECT Gage Sensor & A/C High Pressure Switch
      G02077715Courtesy of GENERAL MOTORS CORP.
  23. Connect the PCV valve hose assembly to the intake manifold and the valve rocker arm cover.
  24. 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 .
  25. Install the accelerator control cable to the throttle shaft and the accelerator control cable bracket.
    Fig 11: Connecting PCV Valve Hose Assembly
    G02077716Courtesy of GENERAL MOTORS CORP.
  26. Install the air cleaner outlet duct (2) on the throttle body assembly.
  27. Tighten the retaining nut (1).

    Tighten 

    Tighten the nut to 2 N.m (18 lb in).

  28. Connect the PCV tube to the air cleaner outlet duct.
  29. Position the coolant reservoir. Install the bolt.

    Tighten 

    Tighten the bolt to 11 N.m (97 lb in).

  30. Install the air cleaner.
  31. Install the engine cover. Refer to Engine Cover Replacement in Interior Trim .
    Fig 12: Installing Air Cleaner Outlet Duct & Retaining Nut
    G02077717Courtesy of GENERAL MOTORS CORP.
scientia non olet · About LEMON Manuals