GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2001 🢒 Tahoe - 2WD 🢒 Engine 🢒 Engine Cooling 🢒 Intake Manifold Replacement

Removal Procedure

Important: The intake manifold, throttle body, fuel rail, and injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.


    Object Number: 700979 Size: SH
  1. Loosen the clamps at the throttle body and air cleaner.
  2. Remove the air cleaner outlet duct.

    3. Object Number: 665445 Size: SH
  3. Loosen the intake manifold sight shield bolt (3).
  4. Remove the sight shield from the bracket (1).
  5. Remove the sight shield bracket (1) and nuts.
  6. Relieve the fuel system pressure. Refer to Fuel Pressure Relief in Engine Controls - 8.1 L.
  7. Disconnect the fuel feed and return pipes. Refer to Metal Collar Quick Connect Fitting Service in Engine Controls - 8.1 L.

    8. Object Number: 750582 Size: SH
  8. Disconnect the engine harness clips from the studs on the front of dash.
  9. Disconnect the engine harness clip from the wheelhouse splash shield.
  10. Disconnect the following electrical connectors:
    11. • Pressure cycling switch (1)
    • Surge tank switch (2)
    • Mass air flow (MAF) sensor (3)
  11. Reposition engine harness branch to top of engine.

    12. Object Number: 750529 Size: SH
  12. Remove the connector position assurance (CPA) retainer at the ignition coil harness.
  13. Disconnect the following electrical connectors:
    14. • Manifold absolute pressure (MAP) sensor (1)
    • Ignition coil harness (2)
    • Engine coolant temperature (ECT) sensor (3)

    Object Number: 750525 Size: SH
  14. Remove the engine harness bolt and studs
  15. Remove the CPA retainer at the ignition coil harness.
  16. Disconnect the following electrical connectors:
    17. • Generator (1)
    • Injector harness (2)
    • Ignition coil harness (3)
    • Throttle position (TP) sensor (4)
    • Electronic throttle control (ETC) (5)
    • Purge valve solenoid (6)
  17. Reposition the engine harness to the drivers side of the engine compartment.

    18. Object Number: 750614 Size: SH
  18. Remove the bypass valve vacuum hose (1) from the intake manifold.

    19. Object Number: 750530 Size: SH
  19. Disconnect the exhaust gas recirculation (EGR) valve electrical connector (1).

    20. Object Number: 635635 Size: SH
  20. Remove the EGR pipe bolts at the EGR adapter.
  21. Reposition the EGR pipe.
  22. Remove and discard the EGR valve pipe gasket.

    23. Object Number: 470641 Size: SH
  23. Remove the secondary air injection (AIR) pipe nut from the fuel rail stud, if equipped.
  24. Remove the AIR pipe bolts at the exhaust manifold, if equipped.
  25. Disconnect the AIR pipe from the AIR pump pipe, if equipped.
  26. Remove and discard the AIR pipe gasket.

    27. Object Number: 470644 Size: SH
  27. Remove the AIR pipe nut from the fuel rail stud, if equipped.
  28. Remove the AIR pipe bolts at the exhaust manifold, if equipped.
  29. Disconnect the AIR pipe from the AIR pump pipe, if equipped.
  30. Remove and discard the AIR pipe gasket.

    31. Object Number: 750615 Size: SH
  31. Reposition the AIR pump hose clamp.
  32. Remove the AIR pump hose (1) from the pump pipe.

    33. Object Number: 470646 Size: SH
  33. Remove the AIR pump pipe bolt from the cylinder head, if equipped.
  34. Remove the AIR pump pipe, if equipped.

    35. Object Number: 470770 Size: SH
  35. Remove the fuel pressure regulator vacuum hose.

    36. Object Number: 470774 Size: SH
  36. If replacing the intake manifold, remove the fuel rail studs.
  37. Remove the fuel rail.

    38. Object Number: 470775 Size: SH
  38. Remove the intake manifold bolts.

    39. Important: Do not attempt to loosen the manifold by prying under the gasket surface with any tool.

  39. Remove the intake manifold.

    40. Object Number: 470779 Size: SH

    Important: The intake manifold gaskets are not reusable.

  40. Remove and discard the intake manifold side gaskets.

    41. Object Number: 470783 Size: SH
  41. Remove and discard the intake manifold end seals.

    42. Object Number: 470786 Size: SH

    Important: The splash shield is secured using a snap-in fit. Do not distort the splash shield. The splash shield is reusable.

  42. Remove the splash shield.
  43. If replacing the intake manifold, refer to Intake Manifold Disassemble in Engine Mechanical - 8.1 L Unit Repair.
  44. Clean the intake manifold. Refer to Intake Manifold Cleaning and Inspection in Engine Mechanical - 8.1 L Unit Repair.

Installation Procedure

    Object Number: 470786 Size: SH
  1. If replacing the intake manifold, refer to Intake Manifold Assemble in Engine Mechanical - 8.1 L Unit Repair.
  2. Install the splash shield.

    3. Object Number: 413867 Size: SH
  3. Ensure the splash shield (2) snap fits between the cylinder heads (1).

    4. Object Number: 470783 Size: SH
  4. Install NEW intake manifold end seals.

    5. Object Number: 470779 Size: SH
  5. Install NEW intake manifold side gaskets onto the cylinder heads.

    6. Object Number: 470778 Size: SH
  6. Ensure the intake manifold gasket tabs align with the hole in the head gasket.
  7. Ensure the intake manifold gasket tabs align with the slot in the intake manifold end seals.

    8. Object Number: 470775 Size: SH
  8. Install the intake manifold gaskets to the cylinder head with THIS SIDE UP stamped facing up.
  9. Install the intake manifold to the engine block.
  10. Apply bolt thread locking material GM P/N 12346004 or equivalent to the intake manifold bolts.

    11. Object Number: 640010 Size: SH
  11. Install the intake manifold.
  12. Apply thread adhesive GM P/N 12345382 or equivalent to a minimum of eight threads of the intake manifold bolts.
  13. Install the intake manifold bolts.
  14. Tighten the intake manifold bolts in sequence, using four passes as shown.

    15. 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 5 N·m (44 lb in) on the second pass.

      3. Inspect the intake manifold joints for signs of intake manifold shifting. Correct as required.

    3. Tighten the intake manifold bolts in sequence to 10 N·m (89 lb in) on the third pass.
    4. Tighten the intake manifold bolts in sequence to 12 N·m (106 lb in) on the final pass.

    Object Number: 470774 Size: SH

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

  15. If replacing the intake manifold, install the fuel rail.
  16. Install the fuel rail studs.

    17. Tighten
    Tighten the fuel rail studs to 12 N·m (106 lb in).


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

    18. Object Number: 470646 Size: SH
  18. Install the AIR pump pipe, if equipped.
  19. Install the AIR pump pipe bolt to the cylinder head, if equipped.

    20. Tighten
    Tighten the AIR pump pipe bolt to 50 N·m (37 lb ft).


    Object Number: 750615 Size: SH
  20. Install the AIR pump hose (1) to the pump pipe.
  21. Reposition the AIR pump hose clamp.

    22. Object Number: 470644 Size: SH
  22. Install a NEW AIR pipe gasket.
  23. Connect the AIR pipe to the AIR pump pipe, if equipped.
  24. Install the AIR pipe bolts at the exhaust manifold, if equipped.
  25. Install the AIR pipe nut to the fuel rail stud, if equipped.

    26. Tighten

        • Tighten the AIR pipe bolts to 25 N·m (18 lb ft).
        • Tighten the AIR pipe nut to 12 N·m (106 lb in).

    Object Number: 470641 Size: SH
  26. Install a NEW AIR pipe gasket.
  27. Connect the AIR pipe to the AIR pump pipe, if equipped.
  28. Install the AIR pipe bolts at the exhaust manifold, if equipped.
  29. Install the (AIR) pipe nut to the fuel rail stud, if equipped.

    30. Tighten

        • Tighten the AIR pipe bolts to 25 N·m (18 lb ft).
        • Tighten the AIR pipe nut to 12 N·m (106 lb in).

    Object Number: 635635 Size: SH
  30. Install a NEW EGR valve pipe gasket.
  31. Position the EGR pipe.
  32. Install the EGR pipe bolts at the EGR adapter.

    33. Tighten
    Tighten the EGR pipe bolts to 30 N·m (22 lb ft).


    Object Number: 750530 Size: SH
  33. Connect the EGR valve electrical connector (1).

    34. Object Number: 750614 Size: SH
  34. Install the bypass valve vacuum hose (1) to the intake manifold.

    35. Object Number: 750525 Size: SH
  35. Position the engine harness over the engine compartment.
  36. Connect the following electrical connectors:
    37. • Generator (1)
    • Injector harness (2)
    • Ignition coil harness (3)
    • TP sensor (4)
    • ETC (5)
    • Purge valve solenoid (6)
  37. Instal the CPA retainer at the ignition coil harness.
  38. Install the engine harness bolt and studs

    39. Tighten

        • Tighten the engine harness bolt to 5 N·m (44 lb in).
        • Tighten the engine harness stud to 10 N·m (89 lb in).

    Object Number: 750529 Size: SH
  39. Connect the following electrical connectors:
    40. • MAP sensor (1)
    • Ignition coil harness (2)
    • ECT sensor (3)
  40. Install the CPA retainer at the ignition coil harness.

    41. Object Number: 750582 Size: SH
  41. Position engine harness branch over the top of engine.
  42. Connect the following electrical connectors:
    43. • Pressure cycling switch (1)
    • Surge tank switch (2)
    • MAF sensor (3)
  43. Connect the engine harness clip to the wheelhouse splash shield.
  44. Connect the engine harness clips to the studs on the front of dash.

    45. Object Number: 665445 Size: SH
  45. Connect the fuel feed and return pipes. Refer to Metal Collar Quick Connect Fitting Service in Engine Controls - 8.1 L.
  46. Install the sight shield bracket (1) and nuts.

    47. Tighten
    Tighten the sight shield bracket nuts to 5 N·m (44 lb in).

  47. Install the sight shield to the bracket (1).
  48. Tighten the intake manifold sight shield bolt (3).

    49. Tighten
    Tighten the intake manifold sight shield bolt to 10 N·m (89 lb in).


    Object Number: 700979 Size: SH
  49. Install the air cleaner outlet duct.
  50. Tighten the clamps at the throttle body and air cleaner.

    51. Tighten
    Tighten the air cleaner outlet duct clamp to 4 N·m (35 lb in).