GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2001 🢒 Express 🢒 Engine 🢒 Engine Mechanical - 6.5L 🢒 Upper Intake Manifold Replacement

Removal Procedure
  1. Remove the engine cover from the vehicle. Refer to Engine Cover Replacement in Interior Trim.

    2. Object Number: 68321 Size: SH

    Important: The upper intake manifold requires removal from the lower intake in order for proper alignment of the lower intake manifolds and the turbocharger during assembly.

  2. Remove the upper intake manifold bolts.
  3. Remove the upper intake manifold and gaskets from the lower intake manifold.

Installation Procedure

    Object Number: 68321 Size: SH
  1. Install new upper intake manifold gaskets to the lower intake manifolds.

    2. Important: Always replace the O-ring between the upper intake manifold and the turbocharger.

  2. Install a new O-ring onto the turbocharger inlet housing.
  3. Lightly lubricate the O-ring with clean engine oil.
  4. Install the upper intake manifold to the lower intake manifolds.

    5. Notice: 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.

  5. Install the upper intake manifold bolts

    6. Tighten
    Tighten the upper intake manifold bolts to 23 N·m (17 lb ft).

  6. Install the engine cover. Refer to Engine Cover Replacement in Interior Trim.