Tuesday, April 10, 2012

Intake Manifold removal for Sierra and Silverado?

The details mentioned here are for GMC Sierra, Chevrolet Silverado car models.
The intake manifold replacing procedure for 4.3L engine and 6.6L Engine car models.

The procedure for both engine models are as follows:-----

Removal & Installation

4.3L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2. Relieve the fuel system pressure
  3. Remove or disconnect the following:

    Negative battery cable
    Air intake duct
    Wiring harness connectors and brackets from the manifold
    Throttle linkage and bracket from the upper manifold
    Cruise control cable, if equipped
    Fuel lines at the rear of the lower intake manifold
    Brake booster vacuum hose from the upper intake manifold
    Ignition coil and bracket
    Purge solenoid and bracket
    Studs and intake manifold attaching bolts, mark for reassembly
    Upper intake manifold
    Distributor housing and rotor, mark for reassembly
    Upper radiator hose from the thermostat housing
    Heater hoses and the bypass hose from the lower intake manifold
    Exhaust Gas Recirculation (EGR) valve
    Transmission dipstick tube, if equipped
    Positive Crankcase Ventilation (PCV) valve and hoses
    Air conditioning compressor and bracket. Without disconnecting, position aside
    Alternator bracket and bolt next to the thermostat housing, if needed
    Lower intake manifold mounting bolts and the lower manifold
To install:
  1. Clean all gasket mating surfaces thoroughly.
  2. Position the new gaskets on the cylinder heads with the port blocking plates at the rear and the words THIS SIDE UP facing up.
  3. Apply a 3 / 16 inch (5mm) bead of RTV to the front and rear sealing surfaces on the engine block. Extend the bead 1 / 2 inch (13mm) up each cylinder head to retain the gasket.
  4. Carefully position the lower intake manifold onto the engine.
  5. Apply GM 1052080 or equivalent sealer to the lower intake manifold bolts
  6. Torque the bolts using 3 steps in the sequence shown:
    1. Step 1: 27 inch lbs. (3 Nm).
    2. Step 2: 106 inch lbs. (12 Nm).
    3. Step 3: 11 ft. lbs. (15 Nm). 

      Fig. Lower intake manifold bolt tightening sequence-4.3L engines
  7. Install or connect the following:

    Alternator bracket and bolts near the thermostat housing, if removed
    Air conditioning compressor
    PCV valve and hose
    Transmission dipstick tube, if equipped
    EGR valve
    Upper radiator and bypass hose to the thermostat housing
  8. Position the upper intake manifold gasket on the lower manifold.
    Be careful not to pinch the injector tubes between the upper and lower manifolds.

    Upper intake manifold. Torque the bolts and studs to 88 inch lbs. (10 Nm).
    Purge control bracket and valve
    Ignition coil
    Brake booster vacuum
    Fuel lines
    Accelerator cable
    Cruise control cable, if equipped
    Wiring harness brackets and connections
    Air intake duct
    Negative battery cable
  9. Refill and bleed the cooling system.
  10. Pressurize the fuel system and check for leaks.

6.6L Engine
Center Manifold
  1. Remove the Exhaust Gas Recirculation (EGR) valve cooler tube.
  2. Remove the intake manifold tube.
  3. Remove and discard the 2 intake manifold tube gaskets.
  4. Remove the turbocharger.
  5. Remove the center intake manifold bolts/nuts.
  6. Pull-up the center intake manifold in order to remove.
  7. Remove and discard the gaskets.
  8. Clean the center intake manifold in cleaning solvent and air dry.
To install:
Fig. Center intake manifold-6.6L engines
  1. Install new center intake manifold gaskets.
  2. Install the center intake manifold.
  3. Install the center intake manifold bolts/nuts and tighten to 89 inch lbs. (10 Nm).
  4. Install the turbocharger.
  5. Install 2 new O-rings onto the intake manifold tube.
  6. Lubricate the O-rings with clean engine oil to aid in the installation.
  7. Install the intake manifold tube.
  8. Install the EGR valve cooler tube.
Left & Right Manifolds
  1. Drain the cooling system.
  2. Remove or disconnect the following:
    The intake manifold uses sealer. If necessary, pry at the area by the common rail bolt holes and be careful to avoid damaging the sealing surfaces.

    Batteries cables
    Center intake manifold
    Fuel junction block
    Left or right fuel rail
    Intake manifold tube
    9 bolts and 2 nuts from the intake manifold. A bolt is located in the manifold opening.

    Intake manifold from the head. Cover the head openings to prevent debris from entering.
  3. Clean all gaskets surface.
To install:
  1. Install or connect the following: 
    The left and right side manifolds are NOT interchangeable.

    1 / 8 in. (2-3mm) wide to 1 / 16 in (0.5-1.5mm) high bead of sealant to the sealing surface of the intake manifold

    Intake manifold
    Bolts and nuts. Tighten to 15 ft. lbs. (20 Nm), in sequence. 

    Fig. Left side intake manifold bolt tightening sequence-6.6L engines

    Fig. Right side intake manifold bolt tightening sequence-6.6L engines
    Intake manifold tube
    Fuel rail
    Fuel junction block
    Negative battery cables
  2. Fill cooling system.

These details will help.


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