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

Removal Procedure
  1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  2. Drain the engine coolant. Refer to Draining and Filling Cooling System in Engine Cooling.
  3. Remove the air cleaner intake duct. Refer to Air Cleaner Assembly Replacement in Engine Controls.
  4. Remove the engine cover. Refer to Engine Cover Replacement in Interior Trim.
  5. Remove the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
  6. Remove the following coolant hoses:
    7. 6.1. Upper radiator hose. Refer to Radiator Hose Replacement - Inlet in Engine Cooling.
    6.2. Inlet heater hose. Refer to Heater Hoses Replacement in Heating, Ventilation and Air Conditioning.
    6.3. Outlet heater hose. Refer to Heater Hoses Replacement in Heating, Ventilation and Air Conditioning.
    6.4. Coolant by-pass hose. Refer to Coolant Bypass Hose Replacement in Engine Cooling.
  7. Disconnect the following electrical connectors.
    8. • SCPI 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 Canister Purge Solenoid Valve Replacement in Engine Controls.
    • Idle air control (IAC) motor. Refer to Idle Air Control Valve Replacement in Engine Controls.
    • Throttle position (TP) sensor. Refer to Throttle Position Sensor Replacement in Engine Controls.
    • Exhaust gas recirculation (EGR) valve. Refer to Exhaust Gas Recirculation Valve Replacement in Engine Controls.
    • Engine coolant temperature (ECT) sensor. Refer to Engine Coolant Temperature Sensor Replacement in Engine Controls.
  8. Remove AIR bypass hose assembly, if so equipped.
  9. Use a twisting motion in order to remove the brake booster vacuum hose, if equipped. Refer to Vacuum Brake Booster Replacement in Brakes.
  10. Remove the distributor from the engine. Refer to Distributor Replacement in Engine Electrical.
  11. Remove the fuel pipes from the rear of the engine. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls.

    12. Object Number: 500661 Size: SH
  12. Remove the accelerator control cable and the cruise control cables, if equipped, from the throttle shaft. Refer to Accelerator Control Cable Replacement in Engine Controls.
  13. Remove the accelerator control cable bracket from the throttle body and the lower intake manifold.
  14. Remove the ignition coil and ICM bracket. Refer to Ignition Coil Replacement and Ignition Control Module Replacement in Engine Controls.
  15. Remove the EGR pipe from the intake manifold. Refer to Exhaust Gas Recirculation Pipe Replacement in Engine Controls.

    16. Object Number: 179249 Size: SH

    Important: It is not necessary to discharge the A/C refrigerant.

  16. Remove the air conditioning (A/C) compressor, if equipped, and set aside. Refer to Compressor Replacement in Heating, Ventilation and Air Conditioning.
  17. Remove the power steering pulley from the power steering pump. Refer to Power Steering Pulley Replacement in Steering.
  18. Remove the power steering pump mounting bracket.
  19. Remove the left side valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side or Valve Rocker Arm Cover Replacement - Right Side.
  20. Remove the right side valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side or Valve Rocker Arm Cover Replacement - Right Side.

    21. Object Number: 66456 Size: SH
  21. Remove the lower intake manifold from the engine.
  22. Clean all sealing surfaces.

Installation Procedure

    Object Number: 66456 Size: SH
  1. Install the lower intake manifold to the engine. Refer to Intake Manifold Installation.
  2. Install the left side valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side or Valve Rocker Arm Cover Replacement - Right Side.
  3. Install the right side valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side or Valve Rocker Arm Cover Replacement - Right Side.
  4. Install the power steering pump mounting bracket.
  5. Install the air conditioning (A/C) compressor, if equipped. Refer to Compressor Replacement in Heating, Ventilation and Air Conditioning.

    6. Object Number: 173206 Size: SH
  6. Connect the exhaust gas recirculation (EGR) pipe to the bracket and the front of the intake manifold. Refer to Exhaust Gas Recirculation Pipe Replacement in Engine Controls.
  7. Install the ignition coil and the ICM bracket. Refer to Ignition Coil Replacement and Ignition Control Module Replacement in Engine Controls.
  8. Install AIR bypass hose assembly, if so equipped.

    9. Object Number: 317197 Size: SH
  9. Install the accelerator control cable bracket to the throttle body and the lower intake manifold. Refer to Accelerator Control Cable Replacement in Engine Controls.
  10. Install the accelerator control cable and the cruise control cable, if equipped, to the throttle shaft. Refer to Accelerator Control Cable Replacement.
  11. Install the fuel pipes to the rear of the engine. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls.
  12. Install the distributor to the engine. Refer to Distributor Replacement.
  13. Install the PCV tube at intake manifold using a twisting motion in order to lock.
  14. Install the vacuum brake booster hose, if equipped.
  15. Connect the following electrical connectors:
    16. • SCPI 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 Canister Purge Solenoid Valve Replacement in Engine Controls.
    • Idle air control (IAC) motor. Refer to Idle Air Control Valve Replacement in Engine Controls.
    • Throttle position (TP) sensor. Refer to Throttle Position Sensor Replacement in Engine Controls.
    • Exhaust gas recirculation (EGR) valve. Refer to Exhaust Gas Recirculation Valve Replacement in Engine Controls.
    • Engine coolant temperature (ECT) sensor. Refer to Engine Coolant Temperature Sensor Replacement in Engine Controls.
  16. Install the AIR bypass hose assembly, if so equipped.
  17. Install the brake booster vacuum hose, if so equipped. Refer to Vacuum Brake Booster Replacement in Brakes.
  18. Install the upper radiator hose. Refer to Radiator Hose Replacement - Inlet in Engine Cooling.
  19. Install the inlet heater hose. Refer to Heater Hoses Replacement in Heating, Ventilation and Air Conditioning.
  20. Install the outlet heater hose. Refer to Heater Hoses Replacement in Heating, Ventilation and Air Conditioning.
  21. Install the coolant bypass hose. Refer to Coolant Bypass Hose Replacement in Engine Cooling.
  22. Install the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
  23. Install the engine cover. Refer to Engine Cover Replacement in Interior Trim.
  24. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls.
  25. Fill the engine with coolant. Refer to Draining and Filling Cooling System in Engine Cooling.
  26. Connect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.