GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 1999 🢒 Savana 🢒 Engine 🢒 Engine Cooling 🢒 Intake Manifold Replacement

Intake Manifold Replacement Upper Manifold

Removal Procedure

    Object Number: 183401 Size: SH
  1. Disconnect the battery negative cable. Refer to Battery Cable Replacement in Engine Electrical.

    2. Remove the engine cover. Refer to Engine Cover Replacement in Interior Trim.

    Remove the air cleaner intake duct. Refer to Air Cleaner Assembly Replacement in Engine Controls -5.0, 5.7L.

  2. Disconnect the following electrical connectors:
    3. • Fuel injector electrical connector
    • Manifold absolute pressure (MAP) sensor
    • Canister purge solenoid
    • Idle air control (IAC) solenoid
    • Throttle position (TP) sensor
  3. Remove the vacuum brake booster hose, if equipped.
  4. Remove the PCV at the intake manifold.

    5. Twist to unlock the PCV.


    Object Number: 176067 Size: SH
  5. Disconnect the spark plug wires from the left side of the distributor cap.
  6. Remove the fuel pipes from the rear of the engine. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls -5.0, 5.7L.
  7. Remove AIR Bypass hose assembly, if so equiped.
  8. Remove the canister purge solenoid from the engine. Refer to EVAP Canister Purge Solenoid Valve Replacement in Engine Controls -5.0, 5.7L.
  9. 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.
  10. Remove the accelerator control cable bracket from the throttle body and set it aside.

    11. Object Number: 66456 Size: SH
  11. Remove the upper intake manifold from the engine. Refer to Intake Manifold Disassemble .
  12. Clean all sealing surfaces. Refer to Intake Manifold Clean and Inspect .

Installation Procedure

    Object Number: 66456 Size: SH
  1. Install the upper intake manifold to the engine. Refer to Intake Manifold Assemble .

    2. 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 to the throttle body.

    3. Tighten
    Tighten the nuts 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 canister purge solenoid to the engine. Refer toEVAP Canister Purge Solenoid Valve Replacement in Engine Controls -5.0, 5.7L.
  5. Install the fuel pipes to the rear of the engine. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls -5.0, 5.7L.

    6. Object Number: 176067 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 A.I.R. Bypass hose assembly, if so equiped.
  8. Install the PCV to the intake manifold. Twist to lock the PCV.
  9. Install the vacuum brake booster hose to the intake manifold, if equipped.
  10. Connect the following electrical connectors:
    11. • Fuel injector electrical connector
    • Manifold absolute pressure (MAP) sensor
    • Canister purge solenoid
    • Idle air control (IAC) solenoid
    • Throttle position (TP) sensor

    Object Number: 183401 Size: SH
  11. Install the air cleaner intake duct. Refer to Air Cleaner Assembly Replacement in Engine Controls-5.0, 5.7L.
  12. Install the engine cover. Refer to Engine Cover Replacement in Interior Trim.
  13. Connect the battery negative cable. Refer to Battery Cable Replacement in engine electrical.

Intake Manifold Replacement Lower Manifold

Removal Procedure
  1. Disconnect the battery negative cable. Refer to Battery Cable Replacement in engine electrical.
  2. Drain the engine coolant. Refer to Cooling System Draining and Filling in engine cooling.
  3. Remove the air cleaner intake duct. Refer to Air Cleaner Assembly Replacement in Engine Controls-5.0, 5.7L.
  4. Remove the engine cover. Refer to Engine Cover Replacement in Interior Trim.
  5. Remove the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement
  6. Remove the following coolant hoses:
  7. Remove the following coolant hoses:
  8. Upper radiator hose. Refer to Radiator Hose Replacement in Engine Cooling.
  9. Inlet heater hose. Refer to Heater Hoses Replacement in HVAC- non ac equipped.
  10. Outlet heater hose. Refer to Heater Hoses Replacement in HVAC-non ac equipped.
  11. Coolant by-pass hose
  12. Disconnect the following electrical connectors.
  13. SCPI injector electrical connector.
  14. Manifold absolute pressure (MAP) sensor
  15. Canister purge solenoid
  16. Idle air control (IAC) motor
  17. Throttle position (TP) sensor
  18. Exhaust gas recirculation (EGR) valve
  19. Engine coolant temperature (ECT) sensor
  20. Remove AIR Bypass hose assembly, if so equipped.
  21. Use a twisting motion in order to remove the brake booster vacuum hose, if equipped.
  22. Remove the distributor from the engine. Refer to Distributor Replacement in engine electrical.
  23. Remove the fuel pipes from the rear of the engine. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls-5.0/5.7L.
  24. 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.
  25. Remove the accelerator control cable bracket from the throttle body.
  26. Remove the ignition coil and ICM bracket. Refer to Ignition Coil and Ignition Coil Module Replacement in Engine Electrical.
  27. Remove the EGR inlet pipe from the intake manifold.

    28. Object Number: 179249 Size: SH

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

  28. Remove the air conditioning (A/C) compressor, if equipped, and set it aside. Refer to Air Conditioning Compressor Replacement in HVAC.
  29. Remove the power steering pulley from the power steering pump. Refer to Power Steering Pump Pulley Replacement in Steering.
  30. Remove the power steering pump mounting bracket . Refer to Accessory Mounting Brackets Replacement .
  31. Remove the left side valve rocker arm cover. Refer to Valve Rocker Arm Cover Removal (Left) .
  32. Remove the right side valve rocker arm cover. Refer to Valve Rocker Arm Cover Removal (Right) .

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

    35. Refer to Intake Manifold Clean and Inspect in Engine Mechanical.

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 .
  3. Install the right side valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement .
  4. Install the power steering pump mounting bracket . Refer to Accessory Mounting Brackets Replacement .
  5. Install the air conditioning (A/C) compressor, if equipped. Refer to Air Conditioning Compressor Replacement in HVAC.

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

    9. Object Number: 216754 Size: SH
  9. Install the accelerator control cable bracket to the throttle body.
  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-5.0/5.7L.
  12. Install the distributor to the engine. Refer to Distributor Removal .
  13. Install the PCV 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.
    • Manifold absolute pressure (MAP) sensor
    • Canister purge solenoid
    • Idle air control (IAC) motor
    • Throttle position (TP) sensor
    • Exhaust gas recirculation (EGR) valve
    • Engine coolant temperature (ECT) sensor
  16. Install the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
  17. Install the engine cover. Refer to Engine Cover Replacement Engine Cover in Interior Trim.
  18. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls.
  19. Fill the engine with coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
  20. Connect the battery negative cable. Refer to Battery Cable Replacement in Engine Electrical.