GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2004 🢒 Avalanche - 4WD 🢒 Engine 🢒 Engine Mechanical - 8.1L 🢒 Intake Manifold Installation

    Object Number: 1351831 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: 1351832 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: 1351833 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: 1351835 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 due to the anaerobic thread adhesive. The final pass of the tightening sequence must be completed before the adhesive starts to cure, or false torque readings and ineffective thread locking may result.
       • DO NOT reuse intake manifold bolts. Install NEW intake manifold bolts during assembly.

  10. Install the NEW intake manifold bolts.

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

  11. Tighten the intake manifold bolts in sequence, using 4 passes.

    12. Tighten

    1. Tighten the intake manifold bolts a first pass in sequence to 5 N·m (44 lb in).
    2. Tighten the intake manifold bolts a second pass in sequence to 8 N·m (71 lb in). Inspect the intake manifold joints for signs of intake manifold shifting. Correct as required.
    3. Tighten the intake manifold bolts a third pass in sequence to 12 N·m (106 lb in).
    4. Tighten the intake manifold bolts a final pass in sequence to 15 N·m (11 lb ft).

    Object Number: 1198692 Size: SH

    Important: Lubricate the injector O-ring seals with clean engine oil and install onto the injector.

  12. Install the fuel injection fuel rail with injectors.
  13. Install the fuel injection fuel rail bolts/studs.

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


    Object Number: 1310037 Size: SH
  14. Install the throttle body gasket (501) and throttle body (502).
  15. Install the throttle body nuts (503).

    16. Tighten
    Tighten the throttle body nuts to 10 N·m (89 lb in).


    Object Number: 1310056 Size: SH
  16. Install the vacuum plug (513).