GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2004 🢒 Express 🢒 Engine 🢒 Engine Mechanical - 4.8L, 5.3L, and 6.0L 🢒 Intake Manifold Installation

    Object Number: 1277097 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.
       • DO NOT use the intake manifold gaskets again. Install NEW intake manifold-to-cylinder head gaskets.

  1. Install NEW intake manifold-to-cylinder head gaskets (514).

    2. Object Number: 1203975 Size: SH
  2. Install the intake manifold.
  3. Apply a 5 mm (0.20 in) band of threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the intake manifold bolts. Refer to Sealers, Adhesives, and Lubricants .

    4. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 63222 Size: SH
  4. Install the intake manifold bolts.

    5. Tighten

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

    Object Number: 1285134 Size: SH
  5. Install the manifold absolute pressure (MAP) sensor (714), if previously removed.

    6. The electrical connector end of the sensor should be facing the front of the engine.


    Object Number: 1201537 Size: SH
  6. Install the positive crankcase ventilation (PCV) hose.
  7. Install the engine coolant air bleed hose and clamp onto the throttle body.

    8. Object Number: 1285135 Size: SH
  8. Install the accelerator control cable bracket (544) and bolts  (545), if applicable.

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


    Object Number: 1277094 Size: SH
  9. Install the evaporative emission (EVAP) purge solenoid (708), bolt (710), and isolator (709).

    10. Tighten
    Tighten the solenoid bolt to 10 N·m (89 lb in).