GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Chevy K Silverado - 4WD 🢒 Engine 🢒 Engine Controls - 4.3L 🢒 Upper Intake Manifold Replacement

Removal Procedure

    Object Number: 781993 Size: SH
  1. Remove the fuel pipes/hoses. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls-4.3L.
  2. Disconnect the cruise control cable from the throttle lever, if equipped.
  3. Remove the cruise control cable from the accelerator control cable bracket, if equipped.

    4. Object Number: 781992 Size: SH
  4. Remove the accelerator cable from the throttle body lever.

    5. Object Number: 781990 Size: SH
  5. Remove the accelerator cable from the accelerator control cable bracket.

    6. Object Number: 782175 Size: SH
  6. Disconnect the following electrical connectors:
    7. • The air conditioning (A/C) compressor clutch (1), if equipped
    • The A/C pressure switch (4), if equipped
  7. Remove the engine wiring harness clip (3) from the accelerator control cable bracket.

    8. Object Number: 398030 Size: SH
  8. Remove the accelerator control cable bracket nuts.
  9. Remove the accelerator control cable bracket with the cables attached, from the throttle body.
  10. Reposition and secure the bracket and cables out of the way.

    11. Object Number: 782174 Size: SH
  11. Disconnect the following electrical connectors:
    12. • The throttle position (TP) sensor (1)
    • The idle air control (IAC) motor (2)
    • The control port injector module (3)
  12. Remove the engine wiring harness clip bolt (4).

    13. Object Number: 782178 Size: SH
  13. Disconnect the following electrical connectors:
    14. • The evaporative emission (EVAP) canister purge solenoid valve (1)
    • The manifold absolute pressure (MAP) sensor (2)

    Object Number: 869711 Size: SH
  14. Disconnect the EVAP canister harness from the purge solenoid valve.

    15. Object Number: 310241 Size: SH
  15. Remove the engine wiring harness bracket nuts.
  16. Remove the engine wiring harness bracket.

    17. Object Number: 782177 Size: SH
  17. Remove the engine wiring harness ground nut and ground wire (4) from the rear of the right cylinder head.

    18. Object Number: 782176 Size: SH
  18. Remove the engine wiring harness rear bracket nut at the EVAP canister purge solenoid valve.
  19. Remove the stud holding the engine wiring harness bracket.
  20. Reposition the engine wiring harness with the bracket aside.

    21. Object Number: 869710 Size: SH
  21. Remove the PCV valve hose from the valve and rocker cover.

    22. Object Number: 869713 Size: SH
  22. Disconnect the power brake booster vacuum hose from the vacuum fitting.

    23. Object Number: 782205 Size: SH
  23. Remove the accelerator cable bracket nuts.
  24. Remove the accelerator cable bracket.

    25. Object Number: 516794 Size: SH
  25. Remove the intake manifold - upper studs.
  26. Remove the front two throttle body studs.
  27. Remove the intake manifold - upper.

    28. Object Number: 516790 Size: SH
  28. Remove and discard the intake manifold - upper gasket.

    29. Object Number: 516773 Size: SH
  29. Remove and discard the O-ring seal from the fuel meter body.

    30. Object Number: 516797 Size: SH
  30. If required, remove the power brake booster vacuum fitting.
  31. Remove and discard the O-ring seal.

    32. Object Number: 869707 Size: SH
  32. If required, remove the PCV valve cover.
  33. Remove and discard the O-ring seal.

    34. Object Number: 12853 Size: SH
  34. If required, remove the rear throttle body stud.
  35. Remove the throttle body.
  36. Remove and discard the throttle body gasket.

    37. Object Number: 480562 Size: SH
  37. If required, remove the MAP sensor.
  38. Remove and discard the MAP sensor seal.

    39. Object Number: 334511 Size: SH
  39. If required, remove the EVAP canister purge solenoid valve studs.
  40. Remove the purge solenoid valve.
  41. Clean and inspect the intake manifold - upper, if necessary. Refer to Intake Manifold Cleaning and Inspection .

Installation Procedure

    Object Number: 334511 Size: SH
  1. If required, install the purge solenoid valve.

    2. 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.

  2. Install the EVAP canister purge solenoid valve studs. If reusing the old studs, apply threadlock GM P/N 12345382, (Canadian P/N 10953489), or equivalent to the threads.

    3. Tighten
    Tighten the studs to 10 N·m (89 lb in).


    Object Number: 480562 Size: SH
  3. If required, install a NEW MAP sensor seal. Apply a small drop of clean engine oil to the seal.
  4. Install the MAP sensor.

    5. Object Number: 12853 Size: SH
  5. If required, install a NEW throttle body gasket.
  6. Install the throttle body.
  7. Install the rear throttle body stud. If reusing the old stud, apply threadlock GM P/N 12345382, (Canadian P/N 10953489), or equivalent to the threads.

    8. Tighten
    Tighten the stud to 9 N·m (80 lb in).


    Object Number: 869707 Size: SH
  8. If required, install a NEW O-ring seal to the PCV cover. Apply clean engine oil to the seal.
  9. Install the PCV valve cover.

    10. Object Number: 516797 Size: SH
  10. If required, install a NEW O-ring seal. Apply clean engine oil to the seal.
  11. Install the power brake booster vacuum fitting.

    12. Object Number: 516773 Size: SH
  12. Install a NEW O-ring seal to the fuel meter body.

    13. Object Number: 516790 Size: SH
  13. Install a NEW upper intake manifold gasket.

    14. Object Number: 516794 Size: SH
  14. Install the intake manifold - upper.
  15. If reusing the old throttle body/intake manifold studs, apply threadlock GM P/N 12345382, (Canadian P/N 10953489), or equivalent to the threads.
  16. Install the front two throttle body studs.
  17. Install the intake manifold - upper studs.

    18. Tighten
    Tighten the studs to 9 N·m (80 lb in).


    Object Number: 782205 Size: SH
  18. Install the accelerator cable bracket.
  19. Install the accelerator cable bracket nuts.

    20. Tighten
    Tighten the nuts to 12 N·m (106 lb in).


    Object Number: 869713 Size: SH
  20. Connect the power brake booster vacuum hose to the vacuum fitting.

    21. Object Number: 869710 Size: SH
  21. Install the PCV valve hose to the valve cover and rocker cover.

    22. Object Number: 782176 Size: SH
  22. Position the engine wiring harness and bracket.
  23. Install the engine wiring harness bracket stud.

    24. Tighten
    Tighten the stud to 25 N·m (18 lb ft).

  24. Install the engine wiring harness rear bracket nut at the EVAP canister purge solenoid valve.

    25. Tighten
    Tighten the nut to 9 N·m (80 lb in).


    Object Number: 782177 Size: SH
  25. Install the engine wiring harness ground nut and ground wire (4) to the rear of the right cylinder head.

    26. Tighten
    Tighten the nut to 16 N·m (12 lb ft).


    Object Number: 310241 Size: SH
  26. Install the engine wiring harness bracket.
  27. Install the engine wiring harness bracket nuts.

    28. Tighten
    Tighten the nuts to 12 N·m (106 lb in).


    Object Number: 869711 Size: SH
  28. Connect the EVAP canister harness to the purge solenoid valve.

    29. Object Number: 782178 Size: SH
  29. Connect the following electrical connectors:
    30. • The EVAP canister purge solenoid valve (1)
    • The MAP sensor (2)

    Object Number: 782174 Size: SH
  30. Connect the following electrical connectors:
    31. • The TP sensor (1)
    • The IAC motor (2)
    • The control port injector module (3)
  31. Install the engine wiring harness clip bolt (4).

    32. Tighten
    Tighten the bolt to 9 N·m (80 lb in).


    Object Number: 398030 Size: SH
  32. Position the bracket and cables.
  33. Install the accelerator control cable bracket with the cables attached, to the throttle body.
  34. Install the accelerator control cable bracket nuts.

    35. Tighten
    Tighten the nuts to 9 N·m (80 lb in).


    Object Number: 782175 Size: SH
  35. Connect the following electrical connectors:
    36. • The A/C compressor clutch (1), if equipped
    • The A/C pressure switch (4), if equipped
  36. Install the engine wiring harness clip (3) to the accelerator control cable bracket.

    37. Object Number: 781990 Size: SH
  37. Install the accelerator cable to the accelerator control cable bracket.

    38. Object Number: 781992 Size: SH
  38. Install the accelerator cable to the throttle body lever.

    39. Object Number: 781993 Size: SH
  39. Install the cruise control cable to the accelerator control cable bracket, if equipped.
  40. Connect the cruise control cable to the throttle lever, if equipped.
  41. Install the fuel pipes/hoses. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls-4.3L.