GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Kodiak C-Series Motorhome (Cutaway) C4/C5 🢒 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 location.

    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 location.

    6. Object Number: 1397570 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: 1397564 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 prior to the curing of the bolt threadlocking and intake manifold sealing materials. Failure to do so may result in false torque readings and ineffective bolt threadlocking.
       • DO NOT reuse the 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 (1-10) in sequence, using 4 passes.

    12. Tighten

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

    Object Number: 470774 Size: SH

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

  12. Install the fuel injection fuel rail.
  13. Install the fuel injection fuel rail studs and/or bolts.

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


    Object Number: 470770 Size: SH
  14. Install the fuel pressure regulator vacuum hose.

    15. Object Number: 873816 Size: SH
  15. Lubricate the O-ring seal of the oil fill tube with clean engine oil.
  16. Install the oil fill tube.
  17. Install the oil fill tube bolt and nut.

    18. Tighten
    Tighten the oil fill tube bolt and nut to 12 N·m (106 lb in).


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

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