4.8L, 5.3L & 6.0L Engines
4.8L, 5.3L, 6.0L & 6.2L Engines
NOTE
The intake manifold, throttle body, fuel injection rail, and fuel injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.
- Remove or disconnect the following:Positive Crankcase Ventilation (PCV) hose and valveManifold Absolute Pressure (MAP) sensor, if requiredEngine coolant air bleed clamp and hose from the throttle bodyKnock sensor connector, if required.Accelerator control cable bracket and bolts, if requiredFuel rail with injectorsEVAP solenoid, bolt, and isolatorIntake manifold boltsIntake manifold with gasketsIntake manifold-to-cylinder head gaskets from the manifold. Discard the intake manifold gaskets.Throttle body and gasket
- Clean the intake manifold in solvent.
- Dry the intake manifold with compressed air.
- Inspect the throttle body and wire harness studs and stud inserts for looseness or damaged threads.
- Inspect the fuel rail bolt inserts for looseness or damaged threads.
- Inspect the intake manifold vacuum passages for debris or restrictions.
- Inspect for damaged or broken vacuum fittings, damaged MAP sensor mounting bore, or broken MAP sensor retaining tabs.
- Inspect the composite intake manifold assembly for cracks or other damage.
- Inspect the areas between the intake runners. Inspect all the gasket sealing surfaces for damage.
- Inspect the fuel injector bores for excessive scoring or damage. Inspect the intake manifold cylinder head deck for warpage.
- Locate a straight edge across the intake manifold cylinder head deck surface. Position the straight edge across a minimum of two runner port openings.
- Insert a feeler gauge between the intake manifold and the straight edge. A intake manifold with warpage in excess of 0.118 in. (3mm) over a 7.87 in. (200mm) area is warped and should be replaced.
To install:
- Install or connect the following:MAP sensorEVAP solenoid, bolt, and isolator. Tighten the bolt to 89 inch lbs. (10 Nm).NEW intake manifold-to-cylinder head gasketsIntake manifold
- Apply a 0.20 in. (5mm) band of threadlock GM P/N 12345382 or equivalent to the threads of the intake manifold bolts.Intake manifold bolts. Tighten intake manifold bolts first pass in sequence to 44 inch lbs. (5 Nm). Tighten intake manifold bolts final pass in sequence to 89 inch lbs. (10 Nm).PCV valve and hoseCoolant air bleed hose and clamp onto the throttle bodyAccelerator control cable bracket and bolts. Tighten the bolts to 89 inch lbs. (10 Nm).
NOTE
The intake manifold, throttle body, fuel injection rail, and fuel injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.
- Remove or disconnect the following:Positive Crankcase Ventilation (PCV) hose and valveManifold Absolute Pressure (MAP) sensor, if requiredEngine coolant air bleed clamp and hose from the throttle bodyKnock sensor connector, if required.Accelerator control cable bracket and bolts, if requiredFuel rail with injectors
EVAP solenoid, bolt, and isolatorIntake manifold boltsIntake manifold with gasketsIntake manifold-to-cylinder head gaskets from the manifold. Discard the intake manifold gaskets.
Throttle body and gasket - Clean the intake manifold in solvent.
- Dry the intake manifold with compressed air.
- Inspect the throttle body and wire harness studs and stud inserts for looseness or damaged threads.
- Inspect the fuel rail bolt inserts for looseness or damaged threads.
- Inspect the intake manifold vacuum passages for debris or restrictions.
- Inspect for damaged or broken vacuum fittings, damaged MAP sensor mounting bore, or broken MAP sensor retaining tabs.
- Inspect the composite intake manifold assembly for cracks or other damage.
- Inspect the areas between the intake runners. Inspect all the gasket sealing surfaces for damage.
- Inspect the fuel injector bores for excessive scoring or damage. Inspect the intake manifold cylinder head deck for warpage.
- Locate a straight edge across the intake manifold cylinder head deck surface. Position the straight edge across a minimum of two runner port openings.
- Insert a feeler gauge between the intake manifold and the straight edge. A intake manifold with warpage in excess of 0.118 in. (3mm) over a 7.87 in. (200mm) area is warped and should be replaced.
To install:
- Install or connect the following:MAP sensorEVAP solenoid, bolt, and isolator. Tighten the bolt to 89 inch lbs. (10 Nm).NEW intake manifold-to-cylinder head gasketsIntake manifold
- Apply a 0.20 in. (5mm) band of threadlock GM P/N 12345382 or equivalent to the threads of the intake manifold bolts.Intake manifold bolts. Tighten intake manifold bolts first pass in sequence to 44 inch lbs. (5 Nm). Tighten intake manifold bolts final pass in sequence to 89 inch lbs. (10 Nm).
PCV valve and hoseCoolant air bleed hose and clamp onto the throttle bodyAccelerator control cable bracket and bolts. Tighten the bolts to 89 inch lbs. (10 Nm).
NOTE
The intake manifold, throttle body, fuel injection rail, and fuel injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.
- Partially drain the engine coolant.
- Remove or disconnect the following:Air cleaner outlet ductEngine sight shieldThrottle actuator motor electrical connectorCoolant air bleed hose from the throttle bodyThrottle bodyFuel rail with injectorsManifold Absolute Pressure (MAP) sensor, if requiredKnock sensor connectorVacuum brake booster hose from the rear of the intake manifoldPositive Crankcase Ventilation (PCV) hose and valveEVAP solenoid, bolt, and isolator
Intake manifold boltsIntake manifold with gasketsIntake manifold-to-cylinder head gaskets from the manifold. Discard the intake manifold gaskets.Throttle body and gasket - Clean the intake manifold in solvent.
- Dry the intake manifold with compressed air.
- Inspect all components for damage, and replace the necessary parts.
- Locate a straight edge across the intake manifold cylinder head deck surface. Position the straight edge across a minimum of two runner port openings.
- Insert a feeler gauge between the intake manifold and the straight edge. An intake manifold with warpage in excess of 0.118 in. (3mm) over a 7.87 in. (200mm) area is warped and should be replaced.
To install:
- Install or connect the following:MAP sensorEVAP solenoid, bolt, and isolator. Tighten the bolt to 89 inch lbs. (10 Nm).NEW intake manifold-to-cylinder head gasketsIntake manifold. Apply a 0.20 in. (5mm) band of threadlock GM P/N 12345382 or equivalent to the threads of the intake manifold bolts.Intake manifold bolts. Tighten intake manifold bolts, in sequence, to 44 inch lbs. (5 Nm). Then, tighten the bolts, in sequence, to 89 inch lbs. (10 Nm).
Vacuum brake booster hose from the rear of the intake manifoldKnock sensor connectorManifold Absolute Pressure (MAP) sensor, if requiredAir cleaner outlet ductFuel rail with injectorsThrottle bodyCoolant air bleed hose to the throttle bodyThrottle actuator motor electrical connectorEngine sight shield
NOTE
The intake manifold, throttle body, fuel injection rail, and fuel injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.
- Remove or disconnect the following:PCV hose and valveMAP sensor, if requiredEngine coolant air bleed clamp and hose from the throttle bodyAccelerator control cable bracket and bolts, if required
EVAP solenoid, bolt, and isolatorIntake manifold boltsIntake manifold with gasketsIntake manifold-to-cylinder head gaskets from the manifold. Discard the intake manifold gaskets.Fuel rail with injectors
Throttle body and gasket - Clean the intake manifold in solvent.
- Dry the intake manifold with compressed air.
- Inspect the throttle body studs and stud inserts for looseness or damaged threads.
- Inspect the wire harness stud and stud insert for looseness or damaged threads.
- Inspect the fuel rail bolt inserts for looseness or damaged threads.
- Inspect the intake manifold vacuum passages for debris or restrictions.
- Inspect for damaged or broken vacuum fittings, damaged MAP sensor mounting bore, or broken MAP sensor retaining tabs.
- Inspect the composite intake manifold assembly for cracks or other damage.
- Inspect the areas between the intake runners. Inspect all the gasket sealing surfaces for damage.
- Inspect the fuel injector bores for excessive scoring or damage. Inspect the intake manifold cylinder head deck for warpage.
- Locate a straight edge across the intake manifold cylinder head deck surface. Position the straight edge across a minimum of two runner port openings.
- Insert a feeler gauge between the intake manifold and the straight edge. A intake manifold with warpage in excess of 3 mm (0.118 in) over a 200 mm (7.87 in) area is warped and should be replaced.
To install:
NOTE
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.
- Install or connect the following:MAP sensorEVAP solenoid, bolt, and isolator. Tighten the EVAP solenoid bolt to 10 Nm (89 inch lbs.).NEW intake manifold-to-cylinder head gasketsIntake manifold. Apply a 5 mm (0.20 in) band of threadlock GM P/N 12345382 or equivalent to the threads of the intake manifold bolts.Intake manifold bolts. Tighten intake manifold bolts first pass in sequence to 5 Nm (44 inch lbs.). Tighten intake manifold bolts final pass in sequence to 10 Nm (89 inch lbs.).
PCV valve and hose. Install the engine coolant air bleed hose and clamp onto the throttle body.Accelerator control cable bracket and bolts, if applicable. Tighten the accelerator control cable bracket bolts to 10 Nm (89 inch lbs.).
NOTE
The intake manifold, throttle body, fuel injection rail, and fuel injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.
- Remove or disconnect the following:PCV hose and valveMAP sensor, if requiredEngine coolant air bleed clamp and hose from the throttle bodyAccelerator control cable bracket and bolts, if required
EVAP solenoid, bolt, and isolatorIntake manifold boltsIntake manifold with gasketsIntake manifold-to-cylinder head gaskets from the manifold. Discard the intake manifold gaskets.Fuel rail with injectors
Throttle body and gasket - Clean the intake manifold in solvent.
- Dry the intake manifold with compressed air.
- Inspect the throttle body studs and stud inserts for looseness or damaged threads.
- Inspect the wire harness stud and stud insert for looseness or damaged threads.
- Inspect the fuel rail bolt inserts for looseness or damaged threads.
- Inspect the intake manifold vacuum passages for debris or restrictions.
- Inspect for damaged or broken vacuum fittings, damaged MAP sensor mounting bore, or broken MAP sensor retaining tabs.
- Inspect the composite intake manifold assembly for cracks or other damage.
- Inspect the areas between the intake runners. Inspect all the gasket sealing surfaces for damage.
- Inspect the fuel injector bores for excessive scoring or damage. Inspect the intake manifold cylinder head deck for warpage.
- Locate a straight edge across the intake manifold cylinder head deck surface. Position the straight edge across a minimum of two runner port openings.
- Insert a feeler gauge between the intake manifold and the straight edge. A intake manifold with warpage in excess of 3 mm (0.118 in) over a 200 mm (7.87 in) area is warped and should be replaced.
To install:
NOTE
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.
- Install or connect the following:MAP sensorEVAP solenoid, bolt, and isolator. Tighten the EVAP solenoid bolt to 10 Nm (89 inch lbs.).NEW intake manifold-to-cylinder head gasketsIntake manifold. Apply a 5 mm (0.20 in) band of threadlock GM P/N 12345382 or equivalent to the threads of the intake manifold bolts.Intake manifold bolts. Tighten intake manifold bolts first pass in sequence to 5 Nm (44 inch lbs.). Tighten intake manifold bolts final pass in sequence to 10 Nm (89 inch lbs.).
PCV valve and hose. Install the engine coolant air bleed hose and clamp onto the throttle body.Accelerator control cable bracket and bolts, if applicable. Tighten the accelerator control cable bracket bolts to 10 Nm (89 inch lbs.).
NOTE
The intake manifold, throttle body, fuel injection rail, and fuel injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.
- Remove or disconnect the following:AlternatorPositive Crankcase Ventilation (PCV) hose and valveManifold Absolute Pressure (MAP) sensor, if requiredEngine coolant air bleed clamp and hose from the throttle bodyKnock sensor connector, if required.Accelerator control cable bracket and bolts, if requiredFuel rail with injectors, if requiredEVAP solenoid, bolt, and isolatorAny additional engine harness attachment points and set asideIntake manifold boltsIntake manifold with gasketsIntake manifold-to-cylinder head gaskets from the manifold. Discard the intake manifold gaskets.
- Clean the intake manifold in solvent.
- Dry the intake manifold with compressed air.
- Inspect the intake manifold vacuum passages for debris or restrictions.
- Inspect for damaged or broken vacuum fittings, damaged MAP sensor mounting bore, or broken MAP sensor retaining tabs.
- Inspect the composite intake manifold assembly for cracks or other damage.
- Inspect the areas between the intake runners. Inspect all the gasket sealing surfaces for damage.
- Inspect the fuel injector bores for excessive scoring or damage. Inspect the intake manifold cylinder head deck for warpage.
- Locate a straight edge across the intake manifold cylinder head deck surface. Position the straight edge across a minimum of two runner port openings.
- Insert a feeler gauge between the intake manifold and the straight edge. A intake manifold with warpage in excess of 0.118 in. (3mm) over a 7.87 in. (200mm) area is warped and should be replaced.
To install:
- Install or connect the following:MAP sensorEVAP solenoid, bolt, and isolator. Tighten the bolt to 89 inch lbs. (10 Nm).NEW intake manifold-to-cylinder head gasketsIntake manifold
- Apply a 0.20 in. (5mm) band of threadlock GM P/N 12345382 or equivalent to the threads of the intake manifold bolts.Intake manifold bolts. Tighten intake manifold bolts first pass in sequence to 44 inch lbs. (5 Nm). Tighten intake manifold bolts final pass in sequence to 89 inch lbs. (10 Nm).
PCV valve and hoseCoolant air bleed hose and clamp onto the throttle bodyAccelerator control cable bracket and bolts. Tighten the bolts to 89 inch lbs. (10 Nm).Alternator
NOTE
The intake manifold, throttle body, fuel injection rail, and fuel injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.
- Remove or disconnect the following:AlternatorPositive Crankcase Ventilation (PCV) hose and valveManifold Absolute Pressure (MAP) sensor, if requiredEngine coolant air bleed clamp and hose from the throttle bodyKnock sensor connector, if required.Accelerator control cable bracket and bolts, if requiredFuel rail with injectors, if requiredEVAP solenoid, bolt, and isolatorAny additional engine harness attachment points and set asideIntake manifold boltsIntake manifold with gasketsIntake manifold-to-cylinder head gaskets from the manifold. Discard the intake manifold gaskets.
- Clean the intake manifold in solvent.
- Dry the intake manifold with compressed air.
- Inspect the intake manifold vacuum passages for debris or restrictions.
- Inspect for damaged or broken vacuum fittings, damaged MAP sensor mounting bore, or broken MAP sensor retaining tabs.
- Inspect the composite intake manifold assembly for cracks or other damage.
- Inspect the areas between the intake runners. Inspect all the gasket sealing surfaces for damage.
- Inspect the fuel injector bores for excessive scoring or damage. Inspect the intake manifold cylinder head deck for warpage.
- Locate a straight edge across the intake manifold cylinder head deck surface. Position the straight edge across a minimum of two runner port openings.
- Insert a feeler gauge between the intake manifold and the straight edge. A intake manifold with warpage in excess of 0.118 in. (3mm) over a 7.87 in. (200mm) area is warped and should be replaced.
To install:
- Install or connect the following:MAP sensorEVAP solenoid, bolt, and isolator. Tighten the bolt to 89 inch lbs. (10 Nm).NEW intake manifold-to-cylinder head gasketsIntake manifold
- Apply a 0.20 in. (5mm) band of threadlock GM P/N 12345382 or equivalent to the threads of the intake manifold bolts.Intake manifold bolts. Tighten intake manifold bolts first pass in sequence to 44 inch lbs. (5 Nm). Tighten intake manifold bolts final pass in sequence to 89 inch lbs. (10 Nm).
PCV valve and hoseCoolant air bleed hose and clamp onto the throttle bodyAccelerator control cable bracket and bolts. Tighten the bolts to 89 inch lbs. (10 Nm).Alternator
Fuel tank removal:---
- Remove the fuel tank.
- Disconnect fuel and evaporative emission (EVAP) lines from the fuel tank module.WARNINGNotice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage tool Joints. Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation.
- Remove the cam lock ring using tool J45722 or equivalent.
- Carefully lift the fuel tank module from the fuel tank, enough to access the quick connect fittings below the module cover.
- Squeeze the quick connect fittings in order to disengage them from the module cover.
- Remove the fuel tank module from the fuel tank.
- Remove and discard the fuel tank module seal.NOTEImportant: Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped. Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring.NOTECheck the lock ring for flatness by placing the lock ring on a flat surface and measuring the clearance between the lock ring and the flat surface using a feeler gauge at 7 points. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.
To install:
- Install the NEW fuel tank module seal onto the fuel tank.
- Position the fuel tank module part way into the fuel tank.
- Connect the quick connect fittings to the module cover.
- Install the fuel tank module into the fuel tank.
- Place the cam lock ring into position.NOTEImportant: Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction.
- Rotate the cam lock ring clockwise using tool J45722 or equivalent until fully seated.
- Connect the fuel and EVAP lines to the fuel tank module.
- Install the fuel tank.
- Remove the sending unit.
- Disconnect the fuel pump electrical connector.
- Remove the fuel lever sensor electrical connector retaining clip.
- Disconnect the fuel level sensor electrical connector.
- Remove the fuel level sensor retaining clip.
- Remove the fuel level sensor (1).
To install:
- Install the fuel level sensor (1).
- Install the fuel level sensor retaining clip.
- Connect the fuel level sensor electrical connector.
- Install the fuel lever sensor electrical connector retaining clip.
- Connect the fuel pump electrical connector.
- Install the sending unit.
PART NUMBER 3 IS SENSOR:--