Intake Manifold: Installation

Install intake manifold using a NEW gasket. Tighten fasteners to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

1. Install NEW intake manifold gaskets (1) to the intake manifold. See Fig 13.
2. Install the intake manifold. See Fig 12.
3. Apply a 0.20" (5 mm) bead of Threadlock (GM P/N 12345382) to the threads of the intake manifold bolts.
4. Install the intake manifold bolts.
   • Tighten the bolts a first pass in sequence to 44 INCH lbs (5 N.m). See Fig 14.
   • Tighten the bolts a final pass in sequence to 89 INCH lbs. (10 N.m).
5. Route the electrical harness into position over the engine.
6. Install the engine harness bracket nut (1). See Fig 11. Tighten the nut to specification. See TORQUE SPECIFICATIONS .
7. Install the vacuum brake booster hose to the rear of the intake manifold. See Fig 10.
8. Install the EVAP purge solenoid vent tube. See Fig 9.
9. Install the heater water shutoff valve actuator inlet hose to the intake manifold. See Fig 8.
10. Install the PCV hose. See Fig 7.
11. Install the knock sensor harness electrical connector to the intake manifold.
12. Connect the following electrical connectors:
    • EVAP purge solenoid (1). See Fig 6.
    • Knock sensor (2).
    • MAP sensor (3).
    • Main coil (5).
    • Fuel injectors (4).
13. Perform the following steps in order to Connect the fuel injector electrical connectors.
    • Install the connectors to their corresponding injectors to ensure correct reassembly.
    • Connect the fuel injector electrical connector.
    • Push the CPA retainer (2) on the connector in 1 click. See Fig 4.
    • Repeat the steps for each injector electrical connector.
14. Install the harness clips to the fuel rail.
15. Connect the generator electrical connector. See Fig 5.
16. Connect the following electrical connectors:
    • Main coil (1). See Fig 3.
    • ETC (2).
    • Fuel injectors (3).
17. Install the electrical harness clips to the fuel rail.
18. Connect the A/C compressor pressure switch electrical connector (2). See Fig 1.
19. Install the harness clip to the cylinder head.
20. Connect the MAF/IAT sensor electrical connector (1). See Fig 2.
21. Install the air cleaner outlet duct. See AIR CLEANER RESONATOR OUTLET DUCT .
22. Install the fuel fill cap.
23. Connect the negative battery cable.
24. Use the following procedure in order to inspect for leaks:
    • Turn the ignition ON, wit the engine OFF, for 2 seconds.
    • Turn the ignition OFF for 10 seconds.
    • Turn the ignition ON, with the engine OFF.
    • Inspect for fuel leaks.

Fig 1: Removing & Installing Intake Manifold (5.3L - 1 Of 13)

Courtesy of GENERAL MOTORS CORP.