GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1999 🢒 Chevy K Pickup - 4WD 🢒 Engine 🢒 Engine Mechanical - 7.4L 🢒 Intake Manifold Assemble

Intake Manifold Assemble Lower


    Object Number: 492032 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 ECT sensor using sealant GM P/N 12346004 or equivalent, if removed.

    2. Tighten
    Tighten the ECT sensor to 20 N·m (15 lb ft).


    Object Number: 492031 Size: SH
  2. Install the thermostat bypass hose fitting using sealant GM P/N 12346004 or equivalent, if removed.

    3. Tighten
    Tighten the thermostat bypass hose fitting to 15 N·m (11 lb ft).


    Object Number: 65322 Size: SH
  3. Install the thermostat and NEW thermostat seal.
  4. Install the coolant outlet housing.
  5. Install the coolant outlet housing bolts.

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


    Object Number: 492021 Size: SH

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

  6. Install the fuel rail assembly in intake manifold. Tilt the rail assembly to install the injectors.
  7. Install the fuel rail stud (1) and bolts (2, 3).

    8. Tighten

        • Tighten the fuel rail stud (1) to 25 N·m (18 lb ft).
        • Tighten the fuel rail bolts (2, 3) to 10 N·m (89 lb in).

    Object Number: 501422 Size: SH
  8. Connect the fuel injector regulator vacuum hose connection to the intake manifold fitting.

    9. Object Number: 351773 Size: SH
  9. Apply lubricant GM P/N 9985770 or equivalent to the MAP sensor seal.

    10. Important: Position the MAP sensor correctly in order to ensure proper clearance for the wiring harness connector.

  10. Install the MAP sensor.
  11. Install the MAP sensor retainer.
  12. Install the MAP sensor retainer nut.

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


    Object Number: 501420 Size: SH
  13. Align the oil fill tube notches (1) parallel to the center line of the crankshaft (2).

    14. Object Number: 501419 Size: SH
  14. Apply a 6.0 mm (0.240 in) bead of sealant GM P/N 9985409 or equivalent to the intake manifold end of the oil fill tube.
  15. Install the oil fill tube, if removed.

Intake Manifold Assemble Upper


    Object Number: 18303 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 throttle body studs, if removed.

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

  2. Install the NEW 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 NEW 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 (RPO K19 only), if removed .
  11. Install the secondary air injection check valve bracket stud.

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


    Object Number: 501418 Size: SH
  12. Install the secondary air injection check valve bracket stud (without RPO K19), if removed.

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


    Object Number: 492023 Size: SH
  13. Install the ECT wiring harness connector bracket, if removed.
  14. Install the ECT wiring harness connector bracket bolt.

    15. Tighten
    Tighten the ECT wiring harness connector bracket bolt to 25 N·m (18 lb ft).


    Object Number: 492027 Size: SH
  15. Install the accelerator control cable bracket, if removed.
  16. Install the accelerator control cable bracket bolt and stud.

    17. Tighten
    Tighten the accelerator control cable bracket bolt and stud to 25 N·m (18 lb ft).