GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2002 🢒 Express 🢒 Body and Accessories 🢒 Interior Trim 🢒 Upper Intake Manifold Replacement

Removal Procedure

Important: You do not have to remove the upper intake manifold in order to remove the lower intake manifold.


    Object Number: 183399 Size: SH
  1. Remove the engine cover. Refer to Engine Cover Replacement in Interior Trim.
  2. Disconnect the PCV tube from the air cleaner outlet duct.

    3. Object Number: 35885 Size: SH
  3. Remove the retaining nut (1) from the air cleaner outlet .
  4. Remove the air cleaner outlet duct (2) from the throttle body assembly.

    5. Object Number: 281851 Size: SH
  5. Disconnect the harness connector of the intake air temperature (IAT) sensor .

    6. Object Number: 422129 Size: SH
  6. Loosen the air cleaner outlet duct from the mass air flow (MAF) sensor.
  7. Remove the air cleaner outlet duct.
  8. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 4.3L.
  9. Disconnect the accelerator control cable from the throttle shaft and the accelerator control cable bracket. Refer to Accelerator Control Cable Replacement in Engine Controls - 4.3L.
  10. Disconnect the cruise control cable, if equipped from the throttle shaft and the accelerator control cable bracket. Refer to Cruise Control Cable Replacement in Cruise Control.

    11. Object Number: 172995 Size: SH
  11. Remove the PCV valve hose assembly from the intake manifold and the valve rocker arm cover.

    12. Object Number: 532770 Size: SH
  12. Disconnect the following electrical connectors:
    13. • The fuel meter body assembly connector (1)
    • The EVAP canister purge solenoid valve (2)
    • The manifold absolute pressure (MAP) sensor (3)

    Object Number: 532760 Size: SH
  13. Disconnect the following electrical connectors:
    14. • The throttle position (TP) sensor (1)
    • The idle air control (IAC) motor (2)
    • The engine coolant temperature (ECT) gauge sensor (3)
    • The A/C high pressure switch (4), if equipped

    Object Number: 339442 Size: SH
  14. Remove the engine wiring harness bracket from the intake manifold stud.
  15. Move and secure the engine wiring harness out of the way.

    16. Object Number: 374900 Size: SH
  16. Disconnect the A/C vacuum hose from the intake manifold.
  17. Remove the power brake booster vacuum hose bracket and nut from the intake manifold stud.
  18. Disconnect the power brake booster vacuum hose from the intake manifold.

    19. Object Number: 398027 Size: SH
  19. Remove the accelerator control cable bracket from the throttle body and the intake manifold.
  20. Remove the EVAP canister purge solenoid. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement in Engine Controls - 4.3L.
  21. Remove the fuel lines from the fuel meter body assembly. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls - 4.3L.
  22. Remove the distributor cap. Refer to Distributor Replacement in Engine Electrical.
  23. Remove the ignition control module. Refer to Ignition Control Module Replacement in Engine Electrical.

    24. Object Number: 516794 Size: SH
  24. Remove the studs for the upper intake manifold.
  25. Remove the upper intake manifold.

    26. Object Number: 516790 Size: SH
  26. Remove the upper intake manifold gasket from the groove.
  27. Discard the gasket.

    28. Object Number: 516773 Size: SH
  28. Remove the seal from the fuel meter body assembly.
  29. Discard the seal.

    30. Important: Do not immerse the assembled upper intake manifold in cleaning solvent.

  30. Clean all sealing surfaces and the inside of the upper intake manifold with a shop towel and cleaning solvent.
  31. Inspect the upper intake manifold for the following:
    32. • Cracks or other damage to the exterior
    • Cracking or damage to the gasket grooves
    • Loose or damaged bolt hole thread inserts

    Object Number: 516804 Size: SH
  32. If replacing the upper intake manifold, turn and remove the power brake booster vacuum tube fitting from the upper intake manifold.
  33. Remove and discard the seal.

    34. Object Number: 516797 Size: SH
  34. If replacing the upper intake manifold, turn and remove the PCV valve cover from the upper intake manifold.
  35. Remove and discard the seal.
  36. Remove the throttle body if replacing the upper intake manifold. Refer to Throttle Body Assembly Replacement .
  37. Remove the MAP sensor if replacing the upper intake manifold. Refer to Manifold Absolute Pressure Sensor Replacement in Engine Controls - 4.3L.

Installation Procedure

    Object Number: 516797 Size: SH
  1. Install the throttle body, if removed. Refer to Throttle Body Assembly Replacement .
  2. Install the MAP sensor, if removed. Refer to Manifold Absolute Pressure Sensor Replacement in Engine Controls - 4.3L.
  3. Install the PCV valve cover, if removed, using the following procedure:
    4. 3.1. Install a NEW seal (O-ring) on the PCV valve cover.
    3.2. Lubricate the seal with clean engine oil.
    3.3. Install the PCV valve cover in the upper intake manifold.
    3.4. Turn and lock the PCV valve cover in position.

    Object Number: 516804 Size: SH
  4. Install the power brake booster vacuum tube fitting, if removed, using the following procedure:
    5. 4.1. Install a NEW seal (O-ring) on the power brake booster vacuum tube fitting.
    4.2. Lubricate the seal with clean engine oil.
    4.3. Install the power brake booster vacuum tube fitting in the upper intake manifold.
    4.4. Turn and lock the power brake booster vacuum tube fitting in position.

    Object Number: 516773 Size: SH
  5. Install a NEW seal on the fuel meter body assembly.
  6. Lubricate the seal with clean engine oil.

    7. Object Number: 516790 Size: SH
  7. Install a NEW upper intake manifold to lower intake manifold gasket in the groove of the upper intake manifold.

    8. Object Number: 516794 Size: SH
  8. Install the upper intake manifold onto the lower intake manifold.
  9. If reusing the fasteners, apply threadlock GM P/N 12345382 or equivalent to the threads of the upper intake manifold attaching bolts.

    10. 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.

  10. Install the upper intake manifold attaching studs.

    11. Tighten

    1. Tighten the upper intake manifold attaching studs on the first pass to 5 N·m (44 lb in).
    2. Tighten the upper intake manifold attaching studs on the final pass to 9 N·m (80 lb in).
  11. Install the fuel lines to the fuel meter body assembly. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls - 4.3L.
  12. Install the distributor cap. Refer to Distributor Replacement in Engine Electrical.
  13. Install the ignition control module. Refer to Ignition Control Module Replacement in Engine Electrical.
  14. Install the EVAP canister purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement in Engine Controls - 4.3L.

    15. Object Number: 398027 Size: SH
  15. Install the accelerator control cable bracket, studs, and nuts to the intake manifold and the throttle body.

    16. Tighten
    Tighten the accelerator control cable bracket nuts and studs to 12 N·m (106 lb in).


    Object Number: 374900 Size: SH
  16. Connect the A/C vacuum hose to the intake manifold.
  17. Install the power brake booster vacuum hose bracket and nut to the intake manifold stud.

    18. Tighten
    Tighten the power brake booster vacuum hose bracket nut to 11 N·m (97 lb in).

  18. Connect the power brake booster vacuum hose to the intake manifold.

    19. Object Number: 339442 Size: SH
  19. Install the bracket for the engine wiring harness on the lower intake manifold stud.
  20. Instal the engine wiring harness bracket nut.

    21. Tighten
    Tighten the engine wiring harness bracket nut to 12 N·m (106 lb in).


    Object Number: 532770 Size: SH
  21. Connect the following electrical connectors:
    22. • The fuel meter body assembly connector (1)
    • The EVAP canister purge solenoid valve (2)
    • The manifold absolute pressure (MAP) sensor (3)

    Object Number: 532760 Size: SH
  22. Connect the following electrical connectors:
    23. • The throttle position (TP) sensor (1)
    • The idle air control (IAC) motor (2)
    • The engine coolant temperature (ECT) gage sensor (3)
    • The A/C high pressure switch (4), if equipped

    Object Number: 172995 Size: SH
  23. Connect the PCV valve hose assembly to the intake manifold and the valve rocker arm cover.
  24. Install the cruise control cable, if equipped to the throttle shaft and the accelerator control cable bracket. Refer to Cruise Control Cable Replacement in Cruise Control.
  25. Install the accelerator control cable to the throttle shaft and the accelerator control cable bracket. Refer to Accelerator Control Cable Replacement in Engine Controls - 4.3L.

    26. Object Number: 422129 Size: SH

    Notice: 

       • Handle the MAF sensor carefully.
       • Do not drop the MAF sensor in order to prevent damage to the MAF sensor.
       • Do not damage the screen located on the air inlet end of the MAF.
       • Do not touch the sensing elements.
       • Do not allow solvents and lubricants to come in contact with the sensing elements.
       • Use a small amount of a soap based solution in order to aid in the installation.

  26. Install the air cleaner outlet duct to the MAF sensor.

    27. Object Number: 281851 Size: SH
  27. Connect the IAT sensor harness connector.

    28. Object Number: 35885 Size: SH
  28. Install the air cleaner outlet duct (2) on the throttle body assembly.
  29. Tighten the retaining nut (1).

    30. Tighten
    Tighten the nut 2 N·m (18 lb in).

  30. Connect the PCV tube to the air cleaner outlet duct.
  31. Install the air cleaner. Refer to Air Cleaner Assembly Replacement in Engine Controls - 4.3L.
  32. Install the engine cover. Refer to Engine Cover Replacement in Interior Trim.