PDF associated:
/Assembly Instructions for 4.8 5.3 6.0L Intake Manifold.pdf
Revision C 2 2009 Assembly Instructions for 4 8 5 3 6 0L Intake Manifold 1 0 Disconnect the negative battery terminal 2 0 Loosen retaining bolt near front of plastic engine cover Raise cover and pull slightly to from the top of the manifold 3 0 Loosen the hose clamps where the air inlet duct connects to the throttle body and the connection of the duct to the air cleaner box Remove the plastic push in pin from the duct mount and remove the air inlet duct 4 0 The wiring harness running down the driver s side of the manifold is secured near the front of the manifold Remove the hex nut securing the harness and move the wiring harness to the side of the intake manifold 5 0 CAUTION Read all of step five prior to actually completing the work 5 1 On the passenger side of the intake about in the middle of the fuel rail you will find a pressure relief valve Remove the cap on the top of the pressure relief valve 5 2 With a towel covering the valve press the needle in the center of the valve downward to release the fuel pressure in the fuel rail assembly A small amount of fuel will come out when the pressure is relieved 5 3 Once the pressure has been relieved put the cap back on to the pressure relief valve 5 4 On the driver side of the manifold is where the connection between the fuel line and the fuel rail assembly Remove the safety clip for this connection 5 5 Using an A C Fuel Line Quick Disconnect Tool disconnect the fuel line from the fuel rail assembly 5 6 Remove the safety clip on all eight of the electrical connectors for the fuel injectors 5 7 Remove all eight electrical connectors from the fuel injectors It is recommended that these are labeled prior to disconnecting to assure they are reinstalled in the proper location 6 0 Looking at the throttle body slide the hose clamp back on the coolant line going to the bottom right corner of the throttle body Remove this coolant line during removal a small amount of coolant will drain from the hose 7 0 Remove the hose on the passenger side of the manifold near the throttle body 8 0 The PCV valve and PCV hose connection is on the driver side near the fire wall Disconnect the hose from the PCV valve and from the intake manifold and remove from engine Remove and discard the rubber hose connector on the end that connected to the intake manifold Set PCV tube aside until reassembly 9 0 Disconnect the electrical connector going to the MAP sensor and set aside to insure it will not be damaged 10 0 Remove the hex head bolt that secures the purge solenoid to the intake manifold Gently rotate while pulling upward to remove the purge solenoid Set the purge solenoid with the hose attached aside to prevent damage 11 0 If equipped remove the bolts holding the EGR tube to the front of the intake Gently pull the EGR tube out of the intake manifold remove the bolts holding the EGR valve to the cylinder head and the bolts holding the EGR tube to the exhaust manifold if required 12 0 If equipped with vacuum boosted brakes disconnect the brake booster hose from the back of the intake manifold 13 0 For mechanical throttle body applications remove three bolts retaining the throttle cable bracket to intake manifold Discard original bolts new bolts will be used to attach to the new intake manifold 14 0 Remove the 10 hex head bolts that mount the intake manifold to the cylinder heads The bolts are captive to the manifold and will not be used to install the new int ake manifold 15 0 Pull up on the intake manifold and place it on angle with the throttle body facing up Remove the three hex nuts securing the throttle body to the intake manifold Remove the throttle body and set aside with the electrical connectors attached to prevent damage 16 0 Remove the intake manifold from the engine Carefully clean the cylinder head mating surface 17 0 Remove the following items from the intake manifold 17 1 Remove the plastic bracket that retains the end of the engine cover by removing the three hex head bolts 17 2 Remove the four hex head bolts that secure the fuel rail Pull the fuel rail straight up to remove the rail and injector assembly from the intake manifold Place the fuel rail assembly on a clean cloth to assure no dirt can get in the fuel injectors 17 3 Remove the fuel injector o rings and replace with the new o rings in the parts bag 17 4 Remove the MAP sensor from the old intake manifold On the new intake manifold the MAP sensor is relocated to the rear wall of the manifold Lightly lubricate the map sensor seal with engine oil and install the map sensor in the new manifold ensuring that the snaps engage Revision C 2 2009 17 5 Install the plastic bracket onto the new intake manifold that retains the rear of the engine cover Use three of the large screws supplied in the parts bag to secure the bracket to the manifold 18 0 The intake manifold is ready to be installed to the engine Place the intake manifold into the valley of the engine with the throttle body flange on a slight incline so that the throttle body can be reinstalled 19 0 NOTE The next two steps must be completed before fastening the manifold to the cylinder heads 19 1 Place the throttle body over the three studs and secure the throttle body with the hex nuts removed when the throttle body was removed from the old manifold Torque nuts to 10Nm 89 in lbs 19 2 With the manifold still on a slight incline also reconnect the electrical connector to the MAP sensor 20 0 Aligning the manifold with the cylinder head Take caution to not damage any of the electrical wires disconnected during removal of the old manifold Also be cautious to not damage the knock sensor wires installed in the valley of the engine 21 0 With the manifold aligned start all ten cylinder head mounting bolts included in the parts bag 22 0 First pass torque all ten bolts to 5Nm 44 in lbs in the sequence noted next to each bolt on the intake manifold 23 0 Final torque all ten bolts to 10Nm 89 in lbs in the sequence noted next to each bolt on the intake manifold 24 0 Reinstall the plastic bracket connected to the wiring harness Place the plastic bracket over the stud on the intake manifold and secure it using the hex nut previously removed from the old manifold 25 0 For mechanical throttle body applications install the throttle cable bracket using three large screws from the parts bag Do not reuse the bolts from your old manifold Torque screws to 10Nm 89 in lbs 26 0 Install the fuel rail assembly into the new intake manifold Press down lightly on each side of the fuel rail to initial seat the fuel injector in their pockets Once the initial seating has been completed press on the fuel rail directly above each injector to fully seat each fuel injector Secure the fuel rail assembly to the manifold using four of the large screws supplied in the parts bag and torque to 10Nm 89 in lbs 27 0 Reinstall the eight electrical connectors to each fuel injector Take caution to make sure that the proper connector is mated up with the proper fuel injector 28 0 Reinstall the safety clip on each of the eight electrical connectors for each fuel injector 29 0 Reinstall the coolant hose to the bottom of the throttle body Once the hose has pushed onto the fitting completely pinch the hose clamp and slide back up the hose to secure the hose to the nipple 30 0 Reinstall the hose on the passenger side of the intake manifold near the throttle body 31 0 Reconnect the fuel line to the fuel rail assembly Take extreme caution to assure this connection is made properly and completely by pulling on the fuel line to assure a secure connection 32 0 Replace the safety clip for this connection 33 0 Install the PCV nylon tube back into manifold Connect one side to the rubber hose installed on the top of the intake manifold Make sure that the nylon tube is pressed into the rubber hose completely to prevent any leakage Push the other end onto completely onto the PCV valve 34 0 Reinstall the purge solenoid by gently rotating and pushing down on the purge solenoid Once the purge solenoid is seated rotate the base to align the screw hole with the mounting hole Use one of the large screws supplied in the parts bag to secure the purge solenoid to the intake manifold and torque to 10Nm 89 i n lbs 35 0 Reinstall the plastic bracket connected to the wiring harness Secure the plastic bracket to the intake manifold using one of the large screws supplied in the parts bag 36 0 If equipped with vacuum boosted brakes remove the hose clamp and vacuum cap on the driver rear side of the intake manifold Slip the corrugated plastic hose protector from the parts bag and the hose clamp just removed from the vacuum cap over the end of the brake vacuum hose Position the hose protector so that the fuel lines will rest on the hose protector Install the hose over the brake boost nipple and install the clamp 37 0 For High Output applications install the double ended stud in the parts bag in the same location as the engine cover front hold down stud on the old intake manifold 38 0 Replace the engine cover making sure to engage the retaining features in the back of the cover Tighten the front engine cover retaining fastener 39 0 Replace the air inlet duct and secure both hose clamps at the throttle body and the air cleaner 40 0 Reconnect the positive battery terminal
