GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2002 🢒 GMC MD Steel Tilt (W Model) 🢒 Engine 🢒 Engine Mechanical - 5.0L and 5.7L 🢒 Upper Intake Manifold Replacement

Removal Procedure

    Object Number: 317197 Size: SH
  1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  2. Remove the engine cover. Refer to Engine Cover Replacement in Interior Trim.
  3. Remove the air cleaner intake duct. Refer to Air Cleaner Assembly Replacement in Engine Controls.
  4. Disconnect the following electrical connectors:
    5. • Fuel injector electrical connector. Refer to Fuel Meter Body Assembly Replacement in Engine Controls.
    • Manifold absolute pressure (MAP) sensor. Refer to Manifold Absolute Pressure Sensor Replacement in Engine Controls.
    • EVAP canister purge solenoid valve. Refer to Evaporative Emission (Evap) Canister Purge Solenoid Valve Replacement in Engine Controls.
    • Idle air control (IAC) solenoid. Refer to Idle Air Control Valve Replacement in Engine Controls.
    • Throttle position (TP) sensor. Refer to Throttle Position Sensor Replacement in Engine Controls.
  5. Remove the vacuum brake booster hose, if equipped.
  6. Remove the PCV tube at the intake manifold.

    7. Twist to unlock the PCV tube.


    Object Number: 500661 Size: SH
  7. Disconnect the spark plug wires from the left side of the distributor cap. Refer to Spark Plug Wire Harness Replacement in Engine Electrical.
  8. Remove the fuel pipes from the rear of the engine. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls.
  9. Remove AIR Bypass hose assembly, if so equipped.
  10. Remove the EVAP canister purge solenoid valve from the engine. Refer to Evaporative Emission (Evap) Canister Purge Solenoid Valve Replacement in Engine Controls.
  11. Remove the accelerator control cable and the cruise control cable, if equipped, from the throttle shaft. Refer to Accelerator Control Cable Replacement in engine controls.
  12. Remove the accelerator control cable bracket from the throttle body and the intake manifold and set it aside.

    13. Object Number: 500681 Size: MH
  13. Remove the upper intake manifold bolts from the engine and then remove the upper intake manifold.
  14. Clean all sealing surfaces.

Installation Procedure

    Object Number: 500681 Size: MH

    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 upper intake manifold to the engine.

    2. Tighten

    1. Tighten the upper intake manifold studs on the first pass to 12 N·m (44 lb in).
    2. Tighten the upper intake manifold studs on the second pass to 10 N·m (89 lb in).

    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 accelerator control cable bracket (3) to the throttle body and the lower intake manifold.

    3. Tighten
    Tighten the bolts and nut to 12 N·m (106 lb in).

  3. Install the accelerator control cable and the cruise control cable, if equipped, to the throttle shaft. Refer to Accelerator Control Cable Replacement in Engine Controls.
  4. Install the EVAP canister purge solenoid valve to the engine. Refer to Evaporative Emission (Evap) Canister Purge Solenoid Valve Replacement in Engine Controls.
  5. Install the fuel pipes to the rear of the engine. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls.

    6. Object Number: 317197 Size: SH
  6. Connect the spark plug wires to the left side of the distributor cap.

    7. The wires and the distributor cap are numbered in order to aid assembly.

  7. Install AIR bypass hose assembly, if so equipped.
  8. Install the PCV tube to the intake manifold. Twist to lock the PCV tube.
  9. Install the vacuum brake booster hose to the intake manifold, if equipped.
  10. Connect the following electrical connectors:
    11. • Fuel injector electrical connector. Refer to Fuel Meter Body Assembly Replacement in Engine Controls.
    • Manifold absolute pressure (MAP) sensor. Refer to Manifold Absolute Pressure Sensor Replacement in Engine Controls.
    • EVAP canister purge solenoid valve. Refer to Evaporative Emission (Evap) Canister Purge Solenoid Valve Replacement in Engine Controls.
    • Idle air control (IAC) solenoid. Refer to Idle Air Control Valve Replacement in Engine Controls.
    • Throttle position (TP) sensor. Refer to Throttle Position Sensor Replacement in Engine Controls.
  11. Install the air cleaner intake duct. Refer to Air Cleaner Assembly Replacement in Engine Controls.
  12. Install the engine cover. Refer to Engine Cover Replacement in Interior Trim.
  13. Connect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.