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Home >> GMC >> 2006 >> Sierra 1500 HD, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1392 (Engine Mechanical - 4.3L) >> Repair Instructions - On Vehicle >> Lower Intake Manifold Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2009 GMC Sierra and 2009 Chevrolet Silverado. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Apply the proper amount of the sealant when assembling this component. Excessive use of the sealant can prohibit the component from sealing properly. A component that is not sealed properly can leak leading to extensive engine damage.
    Fig 1: Applying Patch Of Adhesive To Cylinder Head Side Of Intake Manifold Gasket
    GM38512Courtesy of GENERAL MOTORS CORP.
    NOTE: The intake manifold gasket must be installed while the adhesive is still wet to the touch.
  1. Apply a 4.0 mm (0.157 in) patch of adhesive to the cylinder head side of the intake manifold gasket at each end. Refer to Adhesives, Fluids, Lubricants, and Sealers  for the correct part number.
  2. Install the intake manifold gasket onto the cylinder head. Use the gasket locating pins in order to properly seat the gasket.
    3. Fig 2: Applying Adhesive To Front Top Of Engine Block
    GM26744Courtesy of GENERAL MOTORS CORP.
    NOTE: The 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 to the front top of the engine block. Refer to Adhesives, Fluids, Lubricants, and Sealers  for the correct part number.
  4. Extend the adhesive bead 13 mm (0.50 in) up onto each intake manifold gasket.
    5. Fig 3: Applying Adhesive To Rear Top Of Engine Block
    GM26743Courtesy of GENERAL MOTORS CORP.
  5. Apply a 5 mm (0.197 in) bead of adhesive to the rear top of the engine block. Refer to Adhesives, Fluids, Lubricants, and Sealers  for the correct part number.
  6. Extend the adhesive bead 13 mm (0.50 in) up onto each intake manifold gasket.
    7. Fig 4: View Of Intake Manifold
    GM869728Courtesy of GENERAL MOTORS CORP.
  7. Install the intake manifold.
  8. If reusing the old fasteners, apply threadlock to the threads of the intake manifold - lower bolts. Refer to Adhesives, Fluids, Lubricants, and Sealers  for the correct part number.
  9. Install the intake manifold - lower bolts.
    10. Fig 5: Identifying Lower Intake Manifold Bolts Tightening Sequence
    GM188150Courtesy of GENERAL MOTORS CORP.
    CAUTION: Proper lower intake manifold fastener tightening sequence and torque is critical. Always follow the tightening sequence, and torque the intake manifold bolts using the 3 step method. Failing to do so may distort the crankshaft bearing bore alignment and cause damage to the crankshaft bearings.
    CAUTION: Refer to Fastener Caution .
  10. Tighten the intake manifold - lower bolts in the sequence shown.

    Tighten: 

    1. Tighten the bolts a first pass to 3 N.m (27 lb in).
    2. Tighten the bolts a second pass to 12 N.m (106 lb in).
    3. Tighten the bolts a final pass to 15 N.m (11 lb ft).

    11. Fig 6: View Of Power Steering Pump Bracket
    GM340090Courtesy of GENERAL MOTORS CORP.
  11. Slide the P/S pump bracket rearward.
  12. Install the bolts and the nut for the P/S pump bracket.
  13. Install the P/S pump rear bracket front nut.
  14. Tighten the P/S pump rear bracket nut.

    Tighten:  Tighten the bolts and nuts to 41 N.m (30 lb ft).

  15. Install the drive belt. Refer to Drive Belt Replacement .
    16. Fig 7: View Of Water Pump Inlet Hose & Clamps
    GM182853Courtesy of GENERAL MOTORS CORP.
  16. Install the water pump inlet hose.
  17. Position the water pump inlet hose clamps.
    18. Fig 8: View Of Radiator Inlet Hose & Thermostat Housing
    GM367002Courtesy of GENERAL MOTORS CORP.
  18. Install the radiator inlet hose to the thermostat housing.
  19. Position the radiator inlet hose clamps.
  20. Connect the power brake booster vacuum hose to the vacuum fitting.
    21. Fig 9: Locating PCV Valve Hose At Valve & Rocker Cover
    GM869710Courtesy of GENERAL MOTORS CORP.
  21. Install the PCV valve hose to the valve cover and rocker cover.
    22. Fig 10: Locating Engine Wiring Harness Bracket Stud
    GM1878512Courtesy of GENERAL MOTORS CORP.
  22. Position the engine wiring harness and bracket.
  23. Install the engine wiring harness bracket stud (1).

    Tighten:  Tighten the stud to 25 N.m (18 lb ft).

  24. Install the engine wiring harness rear bracket nut at the EVAP canister purge solenoid valve.

    Tighten:  Tighten the nut to 9 N.m (80 lb in).

    25. Fig 11: View Of Engine Wiring Harness Ground Nut And Ground Wire
    GM1878506Courtesy of GENERAL MOTORS CORP.
  25. Install the engine wiring harness ground nut and ground wire (1) to the rear of the right cylinder head.

    Tighten:  Tighten the nut to 16 N.m (12 lb ft).

    26. Fig 12: Identifying Engine Wiring Harness Bracket Bolt
    GM1878486Courtesy of GENERAL MOTORS CORP.
  26. Install the engine wiring harness bracket bolt (1).

    Tighten:  Tighten the bolt to 12 N.m (106 lb in).

  27. Install the EVAP canister tube. Refer to Evaporative Emission Line Replacement - Engine .
    28. Fig 13: Identifying Oil Pressure Sensor Electrical Connector & Clamp
    GM1878421Courtesy of GENERAL MOTORS CORP.
  28. Connect the oil pressure sensor electrical connector (2).
  29. Install the engine harness clamp (1) to the bracket.
    30. Fig 14: View Of Engine Wiring Harness & Components
    GM1876492Courtesy of GENERAL MOTORS CORP.
  30. Connect the following electrical connectors:
    • The EVAP canister purge solenoid valve (1)
    • The MAP sensor
    31. Fig 15: Identifying Control Port Injector Module
    GM1878388Courtesy of GENERAL MOTORS CORP.
  31. Connect the control port injector module (1).
    32. Fig 16: View Of A/C Pressure Switch & Compressor Clutch Connectors
    GM1878341Courtesy of GENERAL MOTORS CORP.
  32. Connect the following electrical connectors:
    • The A/C compressor clutch (2), if equipped
    • The A/C pressure switch (1), if equipped
    33. Fig 17: View Of Engine Wiring Harness & Components
    GM1876492Courtesy of GENERAL MOTORS CORP.
  33. Connect the engine wiring harness electrical connector (2) to the throttle body.
    34. Fig 18: Identifying Heater Inlet Hose & Water Pump
    GM869714Courtesy of GENERAL MOTORS CORP.
  34. Position the heater inlet and outlet hoses.
  35. Open the heater inlet hose clamp and install the hose to the water pump.
    36. Fig 19: Identifying Intake Manifold Hose
    GM869717Courtesy of GENERAL MOTORS CORP.
  36. Open the heater outlet hose clamp and install the hose to the intake manifold.
    37. Fig 20: Identifying Heater Hose Clamp
    GM869718Courtesy of GENERAL MOTORS CORP.
  37. Install the heater hose clamp (1).
  38. Install the fuel pipes/hoses. Refer to Fuel Line Replacement - Engine .
  39. Install the ignition coil assembly. Refer to Ignition Coil Replacement .
  40. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) or Cooling System Draining and Filling (Static Fill) .
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