GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Generic 🢒 2002 🢒 Unit Repair 🢒 Engine 🢒 Engine Mechanical - 5.7L (LS1 Export) 🢒 Intake Manifold Installation

    Object Number: 490579 Size: SH

    Important: The intake manifold, throttle body, fuel injection rail and fuel injectors may be removed as an assembly. If not servicing the individual components, install the intake manifold as a complete assembly.

  1. Install NEW intake manifold-to-cylinder head gaskets (1).

    2. Object Number: 639607 Size: SH
  2. Install the manifold to the engine.

    3. Object Number: 490927 Size: SH
  3. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the intake manifold bolts (1).

    4. Refer to Sealers, Adhesives, and Lubricants .

    Caution: The fuel rail stop bracket must be installed onto the engine assembly. The stop bracket serves as a protective shield for the fuel rail in the event of a vehicle frontal crash. If the fuel rail stop bracket is not installed and the vehicle is involved in a frontal crash, fuel could be sprayed possibly causing a fire and personal injury from burns.

  4. Install the fuel rail stop bracket (2).

    5. Object Number: 63222 Size: SH

    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 bolts.

    6. Tighten

    1. Tighten the intake manifold bolts a first pass in sequence to 5 N·m (44 lb in).
    2. Tighten the intake manifold bolts a final pass in sequence to 10 N·m (89 lb in).

    Object Number: 639606 Size: SH
  6. Install the knock sensor wire harness connector (1) onto the fuel rail stop bracket (2).

    7. Object Number: 58838 Size: SH
  7. Install the manifold absolute pressure (MAP) sensor, if previously removed.

    8. Object Number: 490573 Size: SH
  8. Install the accelerator control cable bracket (2) and bolts  (1).

    9. Tighten
    Tighten the bracket bolts to 10 N·m (89 lb in).


    Object Number: 379367 Size: MH
  9. Install the positive crankcase ventilation (PCV) valve pipe to the right rocker cover and intake manifold.
  10. Install the PCV strap and nut onto the right front vapor vent pipe stud.

    11. Tighten
    Tighten the PCV strap nut to 12 N·m (106 lb in).


    Object Number: 379366 Size: SH
  11. Install the PCV valve pipe to the left rocker cover.