GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Avalanche - 4WD 🢒 Engine 🢒 Engine Mechanical - 8.1L 🢒 Intake Manifold Installation

    Object Number: 470786 Size: SH
  1. Install the splash shield.

    2. Object Number: 413867 Size: SH
  2. Ensure the splash shield (2) snap fits between the cylinder heads (1).

    3. Object Number: 1302492 Size: SH
  3. Apply a 5 mm (0.2 in) bead of GM P/N 12346141 (Canadian P/N 10953433) sealer (1) to the 4 engine block/cylinder head locations.

    4. Object Number: 470783 Size: SH
  4. Install the new intake manifold end seals.

    5. Object Number: 1302481 Size: SH
  5. Apply a 5 mm (0.2 in) bead of GM P/N 12346141 (Canadian P/N 10953433) sealer (1) onto the end seals at the 4 engine block/cylinder head locations.

    6. Object Number: 470779 Size: SH
  6. Install the new intake manifold side gaskets onto the cylinder heads.

    7. Object Number: 470778 Size: SH
  7. Ensure the intake manifold gasket tabs align with the hole in the head gasket.
  8. Ensure the intake manifold gasket tabs align with the slot in the intake manifold end seals.

    9. Object Number: 470775 Size: SH
  9. Install the intake manifold onto the engine block.

    10. Object Number: 640010 Size: SH

    Notice: Ensure the intake manifold does not shift as the intake manifold bolts are tightened in the proper sequence. Failure to follow the entire intake manifold bolt tightening sequence exactly, may result in an oil leak and serious engine damage.

    Important: 

       • The entire intake manifold tightening sequence must be promptly completed prior to the curing of the bolt threadlocking and intake manifold sealing materials. Failure to do so may result in false torque readings and ineffective bolt threadlocking.
       • DO NOT reuse the intake manifold bolts during assembly.

  10. Apply thread adhesive GM P/N 12345382 (Canadian P/N 10953489) or equivalent to a minimum of 8 threads of the intake manifold bolts.
  11. Install the intake manifold bolts.

    12. Notice: Refer to Fastener Notice in the Preface section.

  12. Tighten the intake manifold bolts 4 passes in sequence:

    13. Tighten

    1. Tighten the intake manifold bolts in sequence to 5 N·m (44 lb in) on the first pass.
    2. Tighten the intake manifold bolts in sequence to 8 N·m (71 lb in) on the second pass. Inspect the intake manifold joints for signs of intake manifold shifting. Correct as required.
    3. Tighten the intake manifold bolts in sequence to 12 N·m (106 lb in) on the third pass.
    4. Tighten the intake manifold bolts in sequence to 15 N·m (12 lb ft) on the final pass.

    Object Number: 470774 Size: SH

    Important: Lubricate the injector O-ring seals with clean engine oil and install onto the spray tip end of each injector.

  13. Install the fuel injection fuel rail.
  14. Install the fuel injection fuel rail studs and/or bolts.

    15. Tighten
    Tighten the fuel injection fuel rail studs and/or bolts to 12 N·m (106 lb in).


    Object Number: 470770 Size: SH
  15. Install the fuel pressure regulator vacuum hose.