GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1996 🢒 Chevy K Pickup - 4WD 🢒 Engine 🢒 Engine Mechanical - 7.4L 🢒 Intake Manifold Assemble

Lower Intake Manifold

    Object Number: 65322 Size: SH

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  1. Install the coolant outlet housing, thermostat, and bolts.

    2. Tighten
    Tighten the coolant outlet housing bolts to 40 N·m (30 lb ft).

  2. Install the coolant temperature sensor.

    3. Tighten
    Tighten the coolant temperature sensor to 20 N·m (15 lb ft).


    Object Number: 19164 Size: SH

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

  3. Install the fuel rail assembly in intake manifold. Tilt the rail assembly to install the injectors.

    4. Object Number: 19162 Size: SH
  4. Install the fuel rail bolts and stud.

    5. Tighten

        • Tighten the fuel rail bolts to 10 N·m (89 lb in).
        • Tighten the fuel rail stud to 25 N·m (18 lb ft).

    Object Number: 351773 Size: SH
  5. Install the MAP sensor, retainer, and nut to the lower intake manifold.

    6. Tighten
    Tighten the MAP sensor retainer nut to 25 N·m (18 lb ft).

Upper Intake Manifold
  1. Install the throttle body studs, if removed.

    2. Tighten
    Tighten the throttle body studs to 12 N·m (106 lb in).


    Object Number: 18303 Size: SH
  2. Install the throttle body gasket.

    3. Object Number: 18302 Size: SH
  3. Install the throttle body.

    4. Object Number: 18299 Size: SH
  4. Install the throttle body nuts.

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


    Object Number: 276413 Size: SH
  5. Install the EGR gasket
  6. Install the EGR valve.
  7. Install the EGR valve bolts.

    8. Tighten

    1. Tighten the EGR valve bolts a first pass to 10 N·m (89 lb in).
    2. Tighten the EGR valve bolts a final pass to 22 N·m (16 lb ft).

    Object Number: 351775 Size: SH
  8. Install the EVAP purge solenoid valve.
  9. Install the EVAP purge solenoid valve bolts.

    10. Tighten
    Tighten the EVAP purge solenoid valve bolts to 12 N·m (106 lb in).


    Object Number: 354044 Size: SH
  10. Install the secondary air injection check valve bracket, if removed (RPO K19 only).
  11. Install the secondary air injection check valve bracket bolt.

    12. Tighten
    Tighten the secondary air injection check valve bracket bolt to 25 N·m (18 lb ft).