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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 >> Upper 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.
    Fig 1: Identifying Purge Solenoid & Nut
    GM1503010Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Fastener Caution .
  1. If required, install the purge solenoid valve.
  2. Install the EVAP canister purge solenoid valve studs. If reusing the old studs, apply threadlock to the threads. Refer to Adhesives, Fluids, Lubricants, and Sealers  for the correct part number.

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

    3. Fig 2: View Of MAP Sensor
    GM480562Courtesy of GENERAL MOTORS CORP.
  3. If required, install a NEW MAP sensor seal. Apply a small drop of clean engine oil to the seal.
  4. Install the MAP sensor.
    5. Fig 3: View Of Throttle Body & Gasket
    GM12853Courtesy of GENERAL MOTORS CORP.
  5. If required, install a NEW throttle body gasket.
  6. Install the throttle body.
  7. Install the rear throttle body stud. If reusing the old stud, apply threadlock to the threads. Refer to Adhesives, Fluids, Lubricants, and Sealers  for the correct part number.

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

    8. Fig 4: Identifying PCV Valve Cover
    GM869707Courtesy of GENERAL MOTORS CORP.
  8. If required, install a NEW O-ring seal to the PCV cover. Apply clean engine oil to the seal.
  9. Install the PCV valve cover.
    10. Fig 5: View Of Power Brake Booster Vacuum O-Ring Seal
    GM516797Courtesy of GENERAL MOTORS CORP.
  10. If required, install a NEW O-ring seal. Apply clean engine oil to the seal.
  11. Install the power brake booster vacuum fitting.
    12. Fig 6: View Of Fuel Meter Body O-Ring Seal
    GM516773Courtesy of GENERAL MOTORS CORP.
  12. Install a NEW O-ring seal to the fuel meter body.
    13. Fig 7: View Of Intake Manifold Upper Gasket
    GM516790Courtesy of GENERAL MOTORS CORP.
  13. Install a NEW upper intake manifold gasket.
    14. Fig 8: View Of Intake Manifold Upper Studs
    GM516794Courtesy of GENERAL MOTORS CORP.
  14. Install the intake manifold - upper.
  15. If reusing the old throttle body/intake manifold studs, apply threadlock to the threads. Refer to Adhesives, Fluids, Lubricants, and Sealers  for the correct part number.
  16. Install the front two throttle body studs.
  17. Install the intake manifold - upper studs.

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

  18. Connect the power brake booster vacuum hose to the vacuum fitting.
    19. Fig 9: Locating PCV Valve Hose At Valve & Rocker Cover
    GM869710Courtesy of GENERAL MOTORS CORP.
  19. Install the PCV valve hose to the valve cover and rocker cover.
    20. Fig 10: Locating Engine Wiring Harness Bracket Stud
    GM1878512Courtesy of GENERAL MOTORS CORP.
  20. Position the engine wiring harness and bracket.
  21. Install the engine wiring harness bracket stud (1).

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

  22. 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).

    23. Fig 11: View Of Engine Wiring Harness Ground Nut & Ground Wire
    GM1878506Courtesy of GENERAL MOTORS CORP.
  23. 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).

    24. Fig 12: View Of EVAP Canister Purge Solenoid Valve Tube Quick Connect Fitting
    GM1876612Courtesy of GENERAL MOTORS CORP.
  24. Position the EVAP canister purge solenoid tube, and connect the tube quick connect fitting (1) to the EVAP purge solenoid valve. Refer to Plastic Collar Quick Connect Fitting Service .
    25. Fig 13: View Of Engine Wiring Harness & Components
    GM1876492Courtesy of GENERAL MOTORS CORP.
  25. Connect the following electrical connectors:
    • The EVAP canister purge solenoid valve (1)
    • The MAP sensor
    26. Fig 14: View Of Engine Wiring Harness Rear Bracket & Bolts
    GM1876871Courtesy of GENERAL MOTORS CORP.
  26. Place the engine wiring harness rear bracket onto the upper intake manifold and install the bolts.

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

    27. Fig 15: View Of Engine Wiring Harness Clips
    GM1876870Courtesy of GENERAL MOTORS CORP.
  27. Install the engine wiring harness clips (1, 2) to the engine harness brackets.
    28. Fig 16: Identifying Control Port Injector Module
    GM1878388Courtesy of GENERAL MOTORS CORP.
  28. Connect the control port injector module (1).
    29. Fig 17: View Of A/C Pressure Switch & Compressor Clutch Connectors
    GM1878341Courtesy of GENERAL MOTORS CORP.
  29. Connect the following electrical connectors:
    • The A/C compressor clutch (2), if equipped
    • The A/C pressure switch (1), if equipped
  30. Install the fuel pipes/hoses. Refer to Fuel Line Replacement - Engine .
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