Diesel Data: Automotive Repair
Home >> Chevy Truck >> 2000 >> Express 1 Ton Van V8-5.7L VIN R >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Intake Manifold >> Service and Repair >> Upper Intake Manifold Replacement

Upper Intake Manifold Replacement


Removal Procedure





1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure.
2. Remove the engine cover. Refer to Engine Cover Replacement.
3. Remove the air cleaner intake duct. Refer to Air Cleaner Assembly Replacement.
4. Disconnect the following electrical connectors:
- Fuel injector electrical connector. Refer to Fuel Meter Body Assembly Replacement.
- Manifold Absolute Pressure (MAP) sensor. Refer to Manifold Absolute Pressure (MAP) Sensor Replacement.
- EVAP canister purge solenoid valve. Refer to Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement.
- Idle Air Control (IAC) solenoid. Refer to Idle Air Control (IAC) Valve Replacement.
- Throttle Position (TP) sensor. Refer to Throttle Position (TP) Sensor Replacement.
5. Remove the vacuum brake booster hose, if equipped.
6. Remove the PCV tube at the intake manifold.
Twist to unlock the PCV tube.





7. Disconnect the spark plug wires from the left side of the distributor cap. Refer to Spark Plug Wire Harness Replacement .
8. Remove the fuel pipes from the rear of the engine. Refer to Fuel Hose/Pipes Replacement (Engine Compartment).
9. Remove AIR Bypass hose assembly, if so equipped.
10. Remove the EVAP canister purge solenoid valve from the engine. Refer to Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement.
11. Remove the accelerator control cable and the cruise control cable, if equipped, from the throttle shaft. Refer to Accelerator Controls Cable Replacement.
12. Remove the accelerator control cable bracket from the throttle body and the intake manifold and set it aside.





13. Remove the upper intake manifold bolts from the engine and then remove the upper intake manifold.
14. Clean all sealing surfaces.


Installation Procedure

Notice: Refer to Fastener Notice in Service Precautions.






AllData Editor NOTE: Other than the two torque passes listed below, the OE Manufacturer did NOT address or supply a bolt tightening sequence for the upper Intake Manifold for this model year, or other model years where this 2 piece manifold setup is used.
A "Play It Safe" final tightening sequence would be to tighten from the center most bolts to the outer most bolts.

1. Install the upper intake manifold to the engine.
1.1. Tighten the upper intake manifold studs on the first pass to 12 Nm (44 inch lbs.).
1.2. Tighten the upper intake manifold studs on the second pass to 10 Nm (89 inch lbs.).

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the accelerator control cable bracket (3) to the throttle body and the lower intake manifold.
- Tighten the bolts and nut to 12 Nm (106 inch lbs.).
3. Install the accelerator control cable and the cruise control cable, if equipped, to the throttle shaft. Refer to Accelerator Controls Cable Replacement.
4. Install the EVAP canister purge solenoid valve to the engine. Refer to Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement.
5. Install the fuel pipes to the rear of the engine. Refer to Fuel Hose/Pipes Replacement Engine Compartment.





6. Connect the spark plug wires to the left side of the distributor cap. The wires and the distributor cap are numbered in order to aid assembly.
7. Install AIR bypass hose assembly, if so equipped.
8. Install the PCV tube to the intake manifold. Twist to lock the PCV tube.
9. Install the vacuum brake booster hose to the intake manifold, if equipped.
10. Connect the following electrical connectors:
- Fuel injector electrical connector. Refer to Fuel Meter Body Assembly Replacement.
- Manifold Absolute Pressure (MAP) sensor. Refer to Manifold Absolute Pressure (MAP) Sensor Replacement.
- EVAP canister purge solenoid valve. Refer to Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement.
- Idle Air Control (IAC) solenoid. Refer to Idle Air Control (IAC) Valve Replacement.
- Throttle Position (TP) sensor. Refer to Throttle Position (TP) Sensor Replacement.
11. Install the air cleaner intake duct. Refer to Air Cleaner Assembly Replacement.
12. Install the engine cover. Refer to Engine Cover Replacement.
13. Connect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure.

Diesel-Data.com