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HOMESERVICE MANUALSCHEVROLET2001CHEVY EXPRESS G3500, VAN PASSENGER EXTENDED, 6.5 FREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 428 (ENGINE MECHANICAL)REPAIR INSTRUCTIONSON-VEHICLE REPAIR INSTRUCTIONSINTAKE MANIFOLD REPLACEMENT - LOWERINSTALLATION PROCEDURE
2001 Chevrolet Chevy Express G3500, Van Passenger Extended, 6.5 F

Installation Procedure

2001 Chevrolet Chevy Express G3500, Van Passenger Extended, 6.5 FSECTION Installation Procedure
WARNING: This page is about a different car, the 2003 Pontiac Aztek and 2003 Buick Rendezvous. However, it is still accessible from the selected car via links, so may be relevant.
  1. If you are replacing the lower intake manifold, perform the following steps.
    • Install the ECT sensor.
    • Install the thermostat.

    Important:  All gasket-mating surfaces need to be free of oil, and foreign material. Use GM P/N 12346139 (Canadian P/N 10953463) or equivalent to clean surfaces.

  2. Install the lower intake manifold gaskets.
    NOTE: When replacing lower intake manifold gasket, a revised intake manifold gasket has been introduced by manufacturer. This new design gasket helps resolve issues related to intake manifold oil/coolant leaks. The gasket requires a revised torque specification and procedure in addition to the use of NEW revised intake manifold bolts. Please review TSB ENGINE OIL OR COOLANT LEAK (INSTALL NEW INTAKE MANIFOLD GASKET) for complete information.
  3. Install the push rods and tighten the valve rocker arms. Refer to VALVE ROCKER ARM AND PUSH ROD INSTALLATION  .
  4. With the gaskets in place apply a small drop 8-10 mm (0.31-0.39 in) of RTV sealer GM P/N 12346286 (Canadian P/N 10953472) or equivalent to the 4 corners of the intake manifold to block joint (1).
    Fig 1: Installing Lower Intake Manifold Gaskets
    G01500519Courtesy of GENERAL MOTORS CORP.
  5. Connect the 2 small drops with a bead of RTV sealer that is between 8-10 mm (0.31-0.39 in) wide and 3.0-5.0 mm (0.12-0.20 in) thick (2).
  6. Install the lower intake manifold.
    NOTE: When replacing lower intake manifold gasket, a revised intake manifold gasket has been introduced by manufacturer. This new design gasket helps resolve issues related to intake manifold oil/coolant leaks. The gasket requires a revised torque specification and procedure in addition to the use of NEW revised intake manifold bolts. Please review TSB ENGINE OIL OR COOLANT LEAK (INSTALL NEW INTAKE MANIFOLD GASKET) for complete information.
  7. Apply sealer GM P/N 12345382, (Canadian P/N 10953489) or the equivalent to the lower intake manifold bolt threads.
  8. Install the lower intake manifold bolts.

    Tighten  . See TSB For Revised Lower Intake Torque

    Fig 2: Installing Lower Intake Manifold Bolts
    G01500520Courtesy of GENERAL MOTORS CORP.
  9. Connect the thermostat bypass hose to the lower intake manifold pipe.
  10. Connect the inlet radiator hose to the engine.
  11. Connect the heater inlet pipe to the lower intake manifold.
  12. Install the power steering pump to the front engine cover.
    Fig 3: Connecting Thermostat Bypass Hose To Lower Intake Manifold Pipe
    G01500521Courtesy of GENERAL MOTORS CORP.
  13. Install the fuel injector rail.
  14. Connect the fuel feed and return pipe to the fuel injector rail.
    Fig 4: Installing Fuel Injector Rail With Injectors
    G01500522Courtesy of GENERAL MOTORS CORP.
  15. Install the fuel feed and return pipe retaining clip.
  16. Install the fuel feed and return pipe retaining clip bolt.

    Tighten 

    Tighten the fuel feed and return pipe retaining clip bolt to 8 N.m (71 lb in).

    Fig 5: Installing Fuel Feed And Return Pipe Retaining Clip
    G01500523Courtesy of GENERAL MOTORS CORP.

    Important:  The fuel injector wiring harness connectors must be connected to their respective fuel injectors. Failure to connect the fuel injector connectors to their respective fuel injectors may result in excessive exhaust emissions and poor engine performance.

  17. Install and connect the fuel injector, MAP and ECT wiring harness.
    Fig 6: Installing Fuel Injector, MAP And ECT Wiring Harness
    G01500524Courtesy of GENERAL MOTORS CORP.
  18. Install the wiring harness to the ECT sensor.
  19. Install the engine right side valve rocker arm cover. Refer to VALVE ROCKER ARM COVER REPLACEMENT - LEFT  .
  20. Install the engine left side valve rocker arm cover. Refer to VALVE ROCKER ARM COVER REPLACEMENT - LEFT  .
  21. Install the upper intake manifold. Refer to INTAKE MANIFOLD REPLACEMENT - UPPER  .
    Fig 7: Installing Wiring Harness To ECT Sensor
    G01500525Courtesy of GENERAL MOTORS CORP.
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.