GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2002 🢒 Savana 🢒 Body and Accessories 🢒 Interior Trim 🢒 Lower Intake Manifold Replacement

Removal Procedure

    Object Number: 175681 Size: SH
  1. Disconnect the battery negative cable from the battery. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Remove the engine cover from the vehicle. Refer to Engine Cover Replacement in Interior Trim.
  3. Remove the air cleaner assembly from the vehicle. Refer to Air Cleaner Assembly Replacement in Engine Controls-6.5L (L65).
  4. Remove the air intake duct from the turbocharger.

    5. Object Number: 68321 Size: SH
  5. Remove the upper intake manifold bolts.
  6. Remove the upper intake manifold.
  7. Remove the gaskets from the lower intake manifold.
  8. Remove the seal from the turbocharger.

    9. Object Number: 104973 Size: SH

    Important: The lower intake comes in two sections. If replacing both the left side and the right side perform all of the following steps. If replacing only the left side perform steps 9 to 22 and step 42 to 44. If replacing only the right side perform steps 22 to 44.

  9. Remove the transmission oil level indicator tube upper section from the upper intake manifold.

    10. Object Number: 565324 Size: SH
  10. Remove the oil level indicator from the tube.
  11. Remove the nut retaining the oil level indicator to the thermostat crossover.
  12. Separate the upper section of the oil level indicator tube from the lower section.

    13. Object Number: 160863 Size: SH
  13. If equipped with rear air conditioning (A/C), remove the rear A/C pipe from the A/C compressor. Refer to Compressor Hose Assembly Replacement in Heating, Ventilation and Air Conditioning.
  14. Remove the nuts retaining the rear A/C pipe brackets from the upper intake manifold (if equipped).
  15. Position the rear A/C pipe our of the way.
  16. Drain the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
  17. Remove the upper radiator hose.

    18. Object Number: 564373 Size: SH
  18. Disconnect the gray engine harness electrical connector.

    19. Object Number: 564366 Size: SH
  19. Remove the electrical harness and retaining brackets from the upper intake manifold (if needed).
  20. Remove the nuts retaining the fuel pipe brackets.

    21. Object Number: 53797 Size: SH
  21. Remove the bracket for retaining the CDR valve from the right side lower intake manifold studs.
  22. Remove the CDR valve.

    23. Object Number: 53790 Size: SH

    Important: The sensors and the solenoids attached to the lower intake manifold require removal in order to prevent damage when cleaning with solvent cleaning.

  23. Disconnect the intake air temperature (IAT) sensor electrical connector.
  24. Remove the IAT sensor.

    25. Object Number: 72260 Size: SH
  25. Disconnect the Boost sensor electrical connector by releasing the locking tab.
  26. Remove the Boost sensor retaining bolts.
  27. Remove the Boost sensor.
  28. Remove the gasket.

    29. Object Number: 72272 Size: SH
  29. Disconnect the glow plug relay electrical connectors by releasing the locking tab.
  30. Remove the hold down nuts on the glow plug relay power supply terminals.
  31. Remove the glow plug relay power supply terminals.

    32. Object Number: 72276 Size: SH
  32. Remove the glow plug relay retaining nuts.
  33. Remove the glow plug relay.

    34. Object Number: 72263 Size: SH
  34. Disconnect the wastegate solenoid wiring harness connector by releasing the locking tab.

    35. Object Number: 72262 Size: SH
  35. Remove the vacuum hose harness.

    36. Object Number: 72266 Size: SH
  36. Remove the wastegate solenoid retaining bolts.
  37. Remove the wastegate solenoid.
  38. Remove the wastegate solenoid mounting bracket retaining nuts.
  39. Remove the wastegate solenoid mounting bracket.

    40. Object Number: 564366 Size: SH
  40. Remove the electrical harness retaining clips.
  41. Position the engine wiring harness out of the way.

    42. Object Number: 68323 Size: SH
  42. Remove the lower intake manifold bolts.
  43. Remove the lower intake manifold and gaskets from the cylinder heads.
  44. Inspect and clean the sealing surfaces.

Installation Procedure

    Object Number: 68323 Size: SH
  1. Install the new gaskets onto the cylinder heads.
  2. Install the intake manifolds.
  3. Apply teflon sealer GM P/N 1236004 on the threads of the studs that are second to the end on both intake manifolds. There are a total of four studs that require the teflon sealer.
  4. Apply threadlocker GM P/N 12345382 on the threads of the remaining studs.

    5. 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.

  5. Install the intake manifold studs.

    6. Tighten
    Tighten the intake manifold studs, (from the center out) to 42 N·m (31 lb ft).

  6. Install the miscellaneous brackets and fuel line brackets on the intake studs.
  7. Install the nuts for the brackets.

    8. Tighten
    Tighten the bracket nuts to 23 N·m (17 lb ft).


    Object Number: 564366 Size: SH
  8. Position the engine wiring harness.
  9. Install the electrical harness in the retaining clips.

    10. Object Number: 72266 Size: SH
  10. Install the wastegate solenoid mounting bracket.
  11. Install the wastegate solenoid mounting bracket retaining nuts.

    12. Tighten
    Tighten the bracket nuts to 23 N·m (17 lb ft).

  12. Instal the wastegate solenoid.
  13. Instal the wastegate solenoid retaining bolts.

    14. Tighten
    Tighten the wastegate solenoid bolts to 3.5 N·m (27 lb in).


    Object Number: 72263 Size: SH
  14. Connect the wastegate solenoid wiring harness connector.

    15. Object Number: 72262 Size: SH
  15. Install the vacuum hose harness.

    16. Object Number: 72276 Size: SH
  16. Install the glow plug relay.
  17. Install the glow plug relay retaining nuts.

    18. Tighten
    Tighten the bracket nuts to 42 N·m (37 lb ft).


    Object Number: 72272 Size: SH
  18. Install the glow plug relay power supply terminals.
  19. Install the hold down nuts on the glow plug relay power supply terminals.

    20. Tighten
    Tighten the terminal nuts to 4 N·m (44 lb in).

  20. Connect the glow plug relay electrical connector.

    21. Object Number: 72260 Size: SH
  21. Install the Boost sensor gasket.
  22. Install the Boost sensor.
  23. Install the Boost sensor retaining bolts.

    24. Tighten
    Tighten the terminal nuts to 3.5 N·m (27 lb in).

  24. Connect the Boost sensor electrical connector.

    25. Object Number: 53790 Size: SH
  25. Install the IAT sensor.

    26. Tighten
    Tighten the IAC sensor to 25 N·m (18 lb ft).

  26. Connect the intake air temperature (IAT) sensor electrical connector.

    27. Object Number: 53797 Size: SH
  27. Install the CDR valve.
  28. Install the bracket for retaining the CDR valve to the right side lower intake manifold studs.

    29. Tighten
    Tighten the bracket nuts to 23 N·m (17 lb ft).


    Object Number: 564366 Size: SH
  29. Instal the electrical harness and retaining brackets and nuts.
  30. Install the nuts retaining the fuel pipe brackets.

    31. Tighten
    Tighten the bracket nuts to 23 N·m (17 lb ft).


    Object Number: 564373 Size: SH
  31. Connect the gray engine harness electrical connector.

    32. Object Number: 160863 Size: SH
  32. Install the upper radiator hose.
  33. If equipped with rear air conditioning (A/C), install the rear A/C pipe to the A/C compressor. Refer to Compressor Hose Assembly Replacement in Heating, Ventilation and Air Conditioning.

    34. Object Number: 68321 Size: SH
  34. Install new upper intake manifold gaskets to the lower intake manifolds.

    35. Important: Always replace the O-ring between the upper intake manifold and the turbocharger.

  35. Install a new O-ring onto the turbocharger inlet housing.
  36. Lightly lubricate the O-ring with clean engine oil.
  37. Install the upper intake manifold to the lower intake manifolds.
  38. Install the upper intake manifold bolts

    39. Tighten
    Tighten the upper intake manifold bolts to 23 N·m (17 lb ft).


    Object Number: 565324 Size: SH
  39. Install a small amount of RTV sealant GM P/N 12346286 to the area on the upper tube where it joins with the lower tube.
  40. Install the upper oil level indicator tube.
  41. Install the nut retaining the oil level indicator tube to the thermostat cross over.

    42. Tighten
    Tighten the oil level indicator tube nut to 22 N·m (16 lb ft).

  42. Install the oil level indicator.
  43. For the 6.5L diesel engine, install the bolt and the nut securing the oil level indicator tube brackets to the engine.

    44. Tighten

        • Tighten the bolt to 47 N·m (35 lb ft).
        • Tighten the nut to 25 N·m (18 lb ft).
  44. Fill the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
  45. Recharge the A/C system, if required. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation, and Air Conditioning.

    46. Object Number: 175681 Size: SH
  46. Install the air intake duct from the turbocharger.
  47. Connect the battery negative cable from the battery. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  48. Install the air cleaner assembly from the vehicle. Refer to Air Cleaner Assembly Replacement in Engine Controls-6.5L (L65).
  49. Install the engine cover from the vehicle. Refer to Engine Cover Replacement in Interior Trim.