GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2005 🢒 TopKick C-Series (Conventional) C4/C5 🢒 Engine 🢒 Engine Mechanical - 7.8L 🢒 Intake Manifold Replacement

Intake Manifold Replacement w/CTF

Removal Procedure
  1. Remove the engine cover. Refer to Engine Cover Replacement .
  2. Remove the charge air cooler pipe from the intake pipe. Refer to Charge Air Cooler Inlet Pipe and Outlet Pipe Replacement .
  3. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  4. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
  5. Disconnect the air temperature sensor connector.
  6. Remove the power steering line clamp fasteners at the intake manifold and the valve cover.
  7. Remove the fuel filter and bracket from the intake manifold. Refer to Fuel Filter Replacement .
  8. Remove the exhaust gas recirculation (EGR) valve. Refer Exhaust Gas Recirculation Valve Replacement .

    9. Object Number: 1340181 Size: SH

    Important: Do not bend the fuel injector lines in any shape or form to ease the removal of the intake manifold.

  9. Remove the fuel lines from the common rail to the fuel injector.
  10. Remove the fuel lines from the supply pump to the common rail.
  11. Remove the fuel injector return line from the fuel injector, fuel common rail and the fuel supply pump.

    12. Object Number: 1340200 Size: SH
  12. Remove the intake manifold bolts.
  13. Remove the intake manifold and gasket.

Installation Procedure

    Object Number: 736688 Size: SH

    Important: Inspect the intake manifold for cracks or damage to the gasket mating surface.

  1. Install the intake manifold and gasket.
  2. Install the intake manifold bolts.

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


    Object Number: 1340181 Size: SH
  3. Install the common fuel rail.

    4. Tighten
    Tighten the intake manifold bolts to 15 N·m  (11 lb ft).

  4. Install the fuel lines from the supply pump to the common rail.
  5. Install the fuel lines from the common rail to the fuel injector.
  6. Install the fuel injector return line from the fuel injector, fuel common rail and the fuel supply pump.
  7. Install the fuel filter and the bracket to the intake manifold. Refer to Fuel Filter Replacement .
  8. Connect the MAP sensor.
  9. Connect the air temperature sensor.
  10. Install the EGR valve . Refer Exhaust Gas Recirculation Valve Replacement .
  11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  12. Install the charge air cooler pipe. Refer to Charge Air Cooler Inlet Pipe and Outlet Pipe Replacement .
  13. Install the engine cover. Refer to Engine Cover Replacement .