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 🢒 Intake Manifold Assemble

    Object Number: 500681 Size: MH
  1. Install the fuel meter body (5) into the lower intake manifold (6).
  2. Install the 8 poppet nozzles into the lower intake manifold (6).
  3. Inspect the poppet nozzles in order to ensure that the poppet nozzles are firmly seated and locked in the lower intake manifold bores.
  4. Install the NEW fuel meter body seal (4) into the groove on the fuel meter body (5).
  5. Install the NEW upper intake manifold to lower intake manifold gasket (3) into the groove of the upper intake manifold (2).
  6. Install the upper intake manifold (2) onto the lower intake manifold (6).
  7. If reusing the fasteners, apply threadlock GM P/N United States 12345382, GM P/N Canada 10953489, or equivalent, to the threads of the upper intake manifold attaching studs (1).

    8. 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.

  8. Install the upper intake manifold studs (1).

    9. Tighten

    1. Tighten the upper intake manifold studs on the first pass to 5 N·m (44 lb in).
    2. Tighten the upper intake manifold studs on the second pass to 10 N·m (89 lb in).

    Object Number: 500680 Size: SH
  9. If reusing the fasteners, apply threadlock GM P/N United States 12345382, GM P/N Canada 10953489, or equivalent, to the threads of the evaporative emission (EVAP) canister purge solenoid valve studs.
  10. Install the EVAP canister purge solenoid valve and studs.

    11. Tighten
    Tighten the EVAP canister purge solenoid valve studs to 10 N·m (89 lb in).

  11. Install the engine wiring harness bracket and nut.

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


    Object Number: 500679 Size: SH
  12. Install the NEW fuel seals (8), black O-rings, into the fuel meter body.
  13. Install the NEW spacer rings (7), flat washers, into the fuel meter body.
  14. Install the NEW fuel seals (6), yellow O-rings, into the fuel meter body.
  15. Install the NEW fuel seal retainers (5) into the fuel meter body.
  16. Install the fuel pipe (3) into the fuel meter body.
  17. Install the fuel pipe retainer (1) and the nuts (2).
  18. If reusing the fastener, apply threadlock GM P/N United States 12345382, GM P/N Canada 10953489, or equivalent, to the threads of the fuel pipe bolt (4).
  19. Install the fuel pipe bolt (4).

    20. Tighten

    1. Tighten the fuel pipe retainer nuts (2) to 3 N·m (27 lb in).
    2. Tighten the fuel pipe bolt (4) to 6 N·m (53 lb in).

    Object Number: 500677 Size: SH
  20. Install a NEW manifold absolute pressure (MAP) sensor seal onto the MAP sensor.
  21. Apply a small amount, approximately 1 drop, of clean engine oil to the MAP sensor seal.
  22. Install the MAP sensor into the upper intake manifold.

    23. Object Number: 500674 Size: SH
  23. Install the ignition coil and studs.

    24. Tighten
    Tighten the ignition coil studs to 12 N·m (106 lb in).


    Object Number: 10932 Size: SH
  24. If reusing the engine coolant temperature (ECT) sensor, apply sealant GM P/N United States 12346004, GM P/N Canada 10953480, or equivalent, to the threads of the ECT sensor.
  25. Install the ECT sensor into the front of the lower intake manifold.

    26. Tighten
    Tighten the ECT sensor to 20 N·m (15 lb ft).


    Object Number: 480565 Size: SH

    Important: The EGR valve must be installed in the original orientation.

  26. Install a NEW exhaust gas recirculation (EGR) valve gasket and the EGR valve.

    27. Object Number: 480563 Size: SH
  27. Install the EGR valve bolts.

    28. Tighten

    1. Tighten the EGR valve bolts on the first pass to 10 N·m (88 lb in).
    2. Tighten the EGR valve bolts on the final pass to 30 N·m (22 lb ft).

    Object Number: 500671 Size: SH
  28. Install the engine coolant thermostat.
  29. Install the water outlet.
  30. Install the water outlet studs.

    31. Tighten
    Tighten the water outlet studs to 25 N·m (18 lb ft).


    Object Number: 500667 Size: SH
  31. Install a NEW throttle body gasket into the groove in the upper intake manifold.
  32. Install the throttle body onto the upper intake manifold.
  33. If reusing the fasteners, apply threadlock GM P/N United States 12345382, GM P/N Canada 10953489, or equivalent, to the threads of the throttle body attaching studs.
  34. Install the throttle body attaching studs.

    35. Tighten
    Tighten the throttle body attaching studs to 9 N·m (80 lb in).


    Object Number: 500661 Size: SH
  35. Install the accelerator control bracket, the bolt, and the nut.

    36. Tighten
    Tighten the accelerator control bracket bolt and the nut to 12 N·m (106 lb in).


    Object Number: 500681 Size: MH
  1. Install the fuel meter body (5) into the lower intake manifold (6).
  2. Install the 8 poppet nozzles into the lower intake manifold (6).
  3. Inspect the poppet nozzles in order to ensure that the poppet nozzles are firmly seated and locked in the lower intake manifold bores.
  4. Install the NEW fuel meter body seal (4) into the groove on the fuel meter body (5).
  5. Install the NEW upper intake manifold to lower intake manifold gasket (3) into the groove of the upper intake manifold (2).
  6. Install the upper intake manifold (2) onto the lower intake manifold (6).
  7. If reusing the fasteners, apply threadlock GM P/N 12345382 or equivalent to the threads of the upper intake manifold attaching studs (1).

    8. 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.

  8. Install the upper intake manifold studs (1).

    9. Tighten

    1. Tighten the upper intake manifold studs on the first pass to 5 N·m (44 lb in).
    2. Tighten the upper intake manifold studs on the second pass to 10 N·m (89 lb in).

    Object Number: 500680 Size: SH
  9. If reusing the fasteners, apply threadlock GM P/N 12345382 or equivalent to the threads of the evaporative emission (EVAP) canister purge solenoid valve studs.
  10. Install the EVAP canister purge solenoid valve and studs.

    11. Tighten
    Tighten the EVAP canister purge solenoid valve studs to 10 N·m (89 lb in).

  11. Install the engine wiring harness bracket and nut.

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


    Object Number: 500679 Size: SH
  12. Install the NEW fuel seals (8) (black O-rings) into the fuel meter body.
  13. Install the NEW spacer rings (7) (flat washers) into the fuel meter body.
  14. Install the NEW fuel seals (6) (yellow O-rings) into the fuel meter body.
  15. Install the NEW fuel seal retainers (5) into the fuel meter body.
  16. Install the fuel pipe (3) into the fuel meter body.
  17. Install the fuel pipe retainer (1) and the nuts (2).
  18. If reusing the fastener, apply threadlock GM P/N 12345382 or equivalent to the threads of the fuel pipe bolt (4).
  19. Install the fuel pipe bolt (4).

    20. Tighten

    1. Tighten the fuel pipe retainer nuts (2) to 3 N·m (27 lb in).
    2. Tighten the fuel pipe bolt (4) to 6 N·m (53 lb in).

    Object Number: 500677 Size: SH
  20. Install a NEW manifold absolute pressure (MAP) sensor seal onto the MAP sensor.
  21. Apply a small amount (1 drop) of clean engine oil to the MAP sensor seal.
  22. Install the MAP sensor into the upper intake manifold.

    23. Object Number: 500674 Size: SH
  23. Install the ignition coil and studs.

    24. Tighten
    Tighten the ignition coil studs to 12 N·m (106 lb in).


    Object Number: 10932 Size: SH
  24. If reusing the engine coolant temperature (ECT) sensor, apply sealant GM P/N 12346004 or equivalent to the threads of the ECT sensor.
  25. Install the ECT sensor into the front of the lower intake manifold.

    26. Tighten
    Tighten the ECT sensor to 20 N·m (15 lb ft).


    Object Number: 480565 Size: SH

    Important: The EGR valve must be installed in the original orientation.

  26. Install a NEW exhaust gas recirculation (EGR) valve gasket and the EGR valve.

    27. Object Number: 480563 Size: SH
  27. Install the EGR valve bolts.

    28. Tighten

    1. Tighten the EGR valve bolts on the first pass to 10 N·m (88 lb in).
    2. Tighten the EGR valve bolts on the final pass to 30 N·m (22 lb ft).

    Object Number: 500671 Size: SH
  28. Install the engine coolant thermostat.
  29. Install the water outlet.
  30. Install the water outlet studs.

    31. Tighten
    Tighten the water outlet studs to 25 N·m (18 lb ft).


    Object Number: 500667 Size: SH
  31. Install a NEW throttle body gasket into the groove in the upper intake manifold.
  32. Install the throttle body onto the upper intake manifold.
  33. If reusing the fasteners, apply threadlock GM P/N 12345382 or equivalent to the threads of the throttle body attaching studs.
  34. Install the throttle body attaching studs.

    35. Tighten
    Tighten the throttle body attaching studs to 9 N·m (80 lb in).


    Object Number: 500661 Size: SH
  35. Install the accelerator control bracket, the bolt, and the nut.

    36. Tighten
    Tighten the accelerator control bracket bolt and the nut to 12 N·m (106 lb in).