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HOMESERVICE MANUALSCHEVROLET2001CHEVY EXPRESS G3500, VAN PASSENGER EXTENDED, 6.5 FREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT VARIANT/TRIMSECTION 9 (ENGINE MECHANICAL - 4.3L UNIT REPAIR)REPAIR INSTRUCTIONSINTAKE MANIFOLD ASSEMBLE (L35)
2001 Chevrolet Chevy Express G3500, Van Passenger Extended, 6.5 F

Intake Manifold Assemble (L35)

2001 Chevrolet Chevy Express G3500, Van Passenger Extended, 6.5 FSECTION Intake Manifold Assemble (L35)
WARNING: This page is about a different variant/trim than selected.
  1. If reusing the fastener, apply threadlock GM P/N United States 12345382, GM P/N Canada 10953489, or equivalent, to the threads of the fuel meter body bracket bolt.
  2. Install the fuel meter body bracket and bolt. Tighten the fuel meter bracket bolt to 10 N.m (89 lb in).
  3. Install the fuel meter body into the fuel meter body bracket.
  4. Install the 6 poppet nozzles into the proper lower intake manifold bores.
    Fig 1: Poppet Nozzles
    G02502991Courtesy of GENERAL MOTORS CORP.
  5. Inspect the poppet nozzles in order to ensure that the poppet nozzles are firmly seated and locked in the lower intake manifold bores.
  6. Install a NEW fuel meter body seal into the groove of the fuel meter body.
  7. Install a NEW upper intake manifold to lower intake manifold gasket into the groove of the upper intake manifold.
  8. Install the upper intake manifold onto the lower intake manifold.
  9. If reusing the fasteners, apply threadlock GM P/N United States 12345382, GM P/N Canada 10953489, or equivalent, to the threads of the upper intake manifold attaching studs.
  10. Install the upper intake manifold attaching studs.
    1. 10.1. Tighten the upper intake manifold attaching studs on the first pass to 5 N.m (44 lb in).
    2. 10.2. Tighten the upper intake manifold attaching studs on the final pass to 9 N.m (80 lb in ).
      3. Fig 2: Upper Intake Manifold
      G02502992Courtesy of GENERAL MOTORS CORP.
  11. If reusing the fasteners, apply threadlock GM P/N United States 12345382, GM P/N Canada 10953489, or equivalent, to the threads of the evaporative emission (EVAP) canister purge solenoid valve studs.
  12. Install the EVAP canister purge solenoid valve and studs. Tighten the EVAP canister purge solenoid valve studs to 10 N.m (89 lb in ).
    13. Fig 3: EVAP Canister Purge Solenoid
    G02502993Courtesy of GENERAL MOTORS CORP.
  13. Install the engine wiring harness bracket and nut. Tighten the engine wiring harness bracket nut to 12 N.m (106 lb in ).
  14. Install the NEW fuel seals (8), black O-rings, into the fuel meter body.
    15. Fig 4: Fuel Meter Body Seals
    G02502994Courtesy of GENERAL MOTORS CORP.
  15. Install the NEW spacer rings (7), flat washers, into the fuel meter body.
  16. Install the NEW fuel seals (6), yellow O-rings, into the fuel meter body.
  17. Install the NEW fuel seal retainers (5) into the fuel meter body.
  18. Install the fuel pipe (3) into the fuel meter body.
  19. Install the fuel pipe retainer bracket (2) onto the fuel pipe.
  20. Install the fuel pipe retainer bracket nuts (1).
  21. If reusing the fastener, apply threadlock GM P/N United States 12345382, GM P/N Canada 10953489, or equivalent, to the threads of the fuel pipe bolt.
  22. Install the fuel pipe bolt (4).
    1. 22.1. Tighten the fuel pipe bracket nuts to 3 N.m (27 lb in ).
    2. 22.2. Tighten the fuel pipe bolt to 6 N.m (53 lb in ).
  23. Install a NEW manifold absolute pressure (MAP) sensor seal onto the MAP sensor.
  24. Apply a small amount, approximately 1 drop, of clean engine oil to the MAP sensor seal.
  25. Install the MAP sensor into the upper intake manifold.
    Fig 5: MAP Sensor
    G02502995Courtesy of GENERAL MOTORS CORP.
  26. Install the ignition coil and studs. Tighten the ignition coil studs to 12 N.m (106 lb in ).
    Fig 6: Ignition Coil & Studs
    G02502996Courtesy of GENERAL MOTORS CORP.
  27. If reusing the engine coolant temperature (ECT) sensor plug (1) or the ECT sensor (2), if equipped, apply sealant GM P/N United States 12346004, GM P/N Canada 10953480, or equivalent, to the threads of the ECT sensor plug (1) or the ECT sensor (2).
    28. Fig 7: ECT Sensor Plug Or ECT Sensor
    G02502997Courtesy of GENERAL MOTORS CORP.
  28. Install the ECT sensor or plug, if equipped, into the front of the lower intake manifold. Tighten the ECT sensor or plug to 20 N.m (15 lb ft).

    Important:  The exhaust gas recirculation (EGR) valve must be installed in the original orientation. Some applications will not have an EGR valve.

  29. Install a NEW EGR valve gasket and the EGR valve.
    Fig 8: EGR Valve & Gasket
    G02502998Courtesy of GENERAL MOTORS CORP.
  30. Install the EGR valve bolts.
    1. 30.1. Tighten the EGR valve bolts on the first pass to 7 N.m (62 lb in ).
    2. 30.2. Tighten the EGR valve bolts on the final pass to 30 N.m (22 Lb ft).
  31. Install the engine coolant thermostat.
  32. Install the water outlet (1 or 2).
  33. Install the water outlet studs. Tighten the water outlet studs to 25 N.m (18 Lb ft).
    Fig 9: Engine Coolant Thermostat & Water Outlet
    G02503000Courtesy of GENERAL MOTORS CORP.
  34. Install a NEW throttle body gasket into the groove in the upper intake manifold.
  35. Install the throttle body onto the upper intake manifold.
    Fig 10: Throttle Body & Upper Intake Manifold
    G02503001Courtesy of GENERAL MOTORS CORP.
  36. If reusing the fasteners, apply threadlock GM P/N United States 12345382, GM P/N Canada 10953489, or equivalent, to the threads of the throttle body attaching studs.
  37. Install the throttle body attaching studs. Tighten the throttle body attaching studs to 9 N.m (80 lb in ).
  38. Install the accelerator control cable bracket, the studs, and the nuts.
    1. 38.1. Tighten the accelerator control cable bracket stud to the intake manifold to 6 N.m (53 lb in ).
    2. 38.2. Tighten the accelerator control cable bracket nuts to 12 N.m (106 lb in ).
    3. 38.3. Tighten the accelerator control cable bracket stud to the throttle body to 12 N.m (106 lb in).
RENDER: 1.0x

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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.