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HOMESERVICE MANUALSCHEVROLET2001CHEVY EXPRESS G2500, VAN PASSENGER EXTENDED, 5.0 MREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 869 (ENGINE MECHANICAL - 8.1L - SERVICE, REPAIR AND DIAGNOSTICS)REPAIR INSTRUCTIONSINTAKE MANIFOLD REPLACEMENTINSTALLATION PROCEDURE
2001 Chevrolet Chevy Express G2500, Van Passenger Extended, 5.0 M

Installation Procedure

2001 Chevrolet Chevy Express G2500, Van Passenger Extended, 5.0 MSECTION Installation Procedure
WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2001 GMC Yukon XL, 2001 GMC Sierra, 2001 GMC Cab & Chassis Sierra, 2001 GMC C3500 HD, and 2001 Chevrolet Suburban. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Intake Manifold Splash Shield
    GM470786Courtesy of GENERAL MOTORS COMPANY
  1. If replacing the intake manifold, replace external components removed from original intake manifold.
  2. Install the splash shield.
    3. Fig 2: View Of Splash Shield Proper Installation Position
    GM413867Courtesy of GENERAL MOTORS COMPANY
  3. Ensure the splash shield (2) snap fits between the cylinder heads (1).
    4. Fig 3: Intake Manifold End Seals
    GM470783Courtesy of GENERAL MOTORS COMPANY
  4. Install NEW intake manifold end seals.
    5. Fig 4: Intake Manifold Gaskets
    GM470779Courtesy of GENERAL MOTORS COMPANY
  5. Install NEW intake manifold side gaskets onto the cylinder heads.
    6. Fig 5: View Of Manifold Gasket Tabs Aligning With Head Gasket Hold & Intake Manifold End Seals
    GM470778Courtesy of GENERAL MOTORS COMPANY
  6. Ensure the intake manifold gasket tabs align with the hole in the head gasket.
  7. Ensure the intake manifold gasket tabs align with the slot in the intake manifold end seals.
    8. Fig 6: Intake Manifold & Bolts
    GM470775Courtesy of GENERAL MOTORS COMPANY
  8. Install the intake manifold gaskets to the cylinder head with THIS SIDE UP stamped facing up.
  9. Install the intake manifold to the engine block.
  10. Apply bolt thread locking material GM P/N 12346004 or equivalent to the intake manifold bolts.
    11. Fig 7: View Of Intake Manifold Bolt Tightening Sequence
    GM640010Courtesy of GENERAL MOTORS COMPANY
  11. Install the intake manifold.
  12. Apply thread adhesive GM P/N 12345382 or equivalent to a minimum of eight threads of the intake manifold bolts.
  13. Install the intake manifold bolts.
  14. Tighten the intake manifold bolts in sequence, using four passes as shown.

    Tighten 

    1. Tighten the intake manifold bolts in sequence to 5 N.m (44 lb in) on the first pass.
    2. Tighten the intake manifold bolts in sequence to 5 N.m (44 lb in) on the second pass.

      Inspect the intake manifold joints for signs of intake manifold shifting. Correct as required.

    3. Tighten the intake manifold bolts in sequence to 10 N.m (89 lb in) on the third pass.
    4. Tighten the intake manifold bolts in sequence to 12 N.m (106 lb in) on the final pass.
    15. Fig 8: Fuel Rail & Studs
    GM470774Courtesy of GENERAL MOTORS COMPANY
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.