GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Kodiak C-Series (Conventional) C6/C7/C8 🢒 Engine 🢒 Engine Mechanical - 6.6L 🢒 Intake Manifold Tube Replacement

Removal Procedure

    Object Number: 1867950 Size: SH
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement
  3. Remove the right charge air cooler pipe. Refer to Charged Air Cooler Hoses/Pipes Replacement.
  4. Disconnect the engine harness electrical connector (1) from the manifold absolute pressure (MAP) sensor.
  5. Disconnect the engine harness electrical connector (2) from the intake air heater (IAH).
  6. Disconnect the engine harness electrical connector (3) from the intake air valve.
  7. Remove the 2 engine harness clamp bolts (4).

    8. Object Number: 1867955 Size: SH
  8. Remove the front intake manifold tube bolt.
  9. Reposition the positive battery cable boot.
  10. Remove the positive battery cable nut at the IAH.
  11. Remove the positive battery cable from the IAH stud.

    12. Object Number: 1867966 Size: SH
  12. Remove the harness retainer bolt.
  13. Remove the 2 front intake manifold tube nuts.
  14. Remove the front intake manifold tube bolt.

    15. Object Number: 1867968 Size: SH
  15. Remove the rear intake manifold tube bolt and 2 nuts.

    16. Object Number: 1868000 Size: SH
  16. Remove the intake manifold tube.
  17. Remove and discard the 2 metal EGR gaskets from the EGR valve.
  18. Remove and discard the steel gasket from the center intake manifold.

    19. Object Number: 1865958 Size: SH
  19. If necessary, remove the lower intake manifold tube.
  20. If replacing the intake manifold tube perform the following steps, otherwise proceed to step 5 in the installation procedure.
  21. Remove the MAP sensor bolt (1).
  22. Remove the MAP sensor (2) and bracket (3).

    23. Object Number: 1865972 Size: SH
  23. Remove the air intake valve bolts (1).
  24. Remove the air intake valve (2) and the IAH (3) from the intake manifold tube.

Installation Procedure

    Object Number: 1865972 Size: SH
  1. Position the IAH (3) and the air intake valve (2) to the intake manifold tube.

    2. Caution: Refer to Fastener Caution in the Preface section.

  2. Install the air intake valve bolts.

    3. Tighten
    Tighten the bolts to 20 N·m (15 lb ft).


    Object Number: 1865958 Size: SH
  3. Install the MAP sensor (2) and bracket (3).
  4. Install the MAP sensor bolt (1).

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


    Object Number: 1868000 Size: SH
  5. Install a NEW steel gasket onto the center intake manifold.
  6. Install NEW metal EGR gaskets onto the EGR valve.
  7. Install the intake manifold tube.

    8. Object Number: 1867968 Size: SH
  8. Install the rear intake manifold tube nuts and bolt.

    9. Tighten
    Tighten the bolt/nut to 25 N·m (18 lb ft).


    Object Number: 1867955 Size: SH
  9. Install the front intake manifold tube bolt.

    10. Tighten
    Tighten the nut to 25 N·m (18 lb ft).

  10. Install the 2 front intake manifold tube nuts.

    11. Tighten
    Tighten the bolt to 25 N·m (18 lb ft).


    Object Number: 1867955 Size: SH
  11. Install the front intake manifold tube bolt.

    12. Tighten
    Tighten the bolt to 25 N·m (18 lb ft).


    Object Number: 1867950 Size: SH
  12. Connect the engine harness electrical connector (3) to the intake air valve.
  13. Connect the engine harness electrical connector (2) to the IAH.
  14. Connect the engine harness electrical connector (1) to the MAP sensor.
  15. Install the 2 engine harness clamp bolts (4).

    16. Tighten
    Tighten the bolts to 25 N·m (18 lb ft).

  16. Install the right charge air cooler pipe. Refer to Charged Air Cooler Hoses/Pipes Replacement.
  17. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.
  18. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.