GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2009 🢒 Savana - AWD 🢒 Engine 🢒 Engine Mechanical - 4.3L 🢒 Upper Intake Manifold Replacement

Removal Procedure
  1. Remove the engine cover. Refer to Engine Cover Replacement.
  2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
  3. Remove the fuel pipes/hoses. Refer to Fuel Hose/Pipes Replacement - Engine Compartment.
  4. Disconnect the air conditioning (A/C) compressor clutch, if equipped.

    5. Object Number: 1934811 Size: SH
  5. Disconnect the control port injector module (1).

    6. Object Number: 1935027 Size: SH
  6. Disconnect the following electrical connectors:
    7. • The throttle body actuator (1)
    • The manifold absolute pressure (MAP) sensor (2)
    • The evaporative emission (EVAP) canister purge solenoid valve (3)

    Object Number: 1935055 Size: SH
  7. Disconnect EVAP canister purge solenoid valve tube quick connect fitting (1) from the EVAP purge solenoid valve. Refer to Plastic Collar Quick Connect Fitting Service.
  8. Reposition the tube out of the way.

    9. Object Number: 869710 Size: SH
  9. Remove the positive crankcase ventilation (PCV) valve hose from the valve and rocker cover.
  10. Reposition the engine wiring harness aside.
  11. Disconnect the power brake booster vacuum hose from the vacuum fitting.

    12. Object Number: 516794 Size: SH
  12. Remove the intake manifold - upper studs.
  13. Remove the front 2 throttle body studs.
  14. Remove the intake manifold - upper.

    15. Object Number: 516790 Size: SH
  15. Remove and discard the intake manifold - upper gasket.

    16. Object Number: 516773 Size: SH
  16. Remove and discard the O-ring seal from the fuel meter body.

    17. Object Number: 516797 Size: SH
  17. If required, remove the power brake booster vacuum fitting.
  18. Remove and discard the O-ring seal.

    19. Object Number: 869707 Size: SH
  19. If required, remove the PCV valve cover.
  20. Remove and discard the O-ring seal.

    21. Object Number: 12853 Size: SH
  21. If required, remove the rear throttle body stud.
  22. Remove the throttle body.
  23. Remove and discard the throttle body gasket.

    24. Object Number: 480562 Size: SH
  24. If required, remove the MAP sensor.
  25. Remove and discard the MAP sensor seal.

    26. Object Number: 1503010 Size: SH
  26. If required, remove the EVAP canister purge solenoid valve studs.
  27. Remove the purge solenoid valve.
  28. Clean and inspect the intake manifold - upper, if necessary. Refer to Intake Manifold Cleaning and Inspection.

Installation Procedure

    Object Number: 1503010 Size: SH
  1. If required, install the purge solenoid valve.

    2. Caution: Refer to Fastener Caution in the Preface section.

  2. Install the EVAP canister purge solenoid valve studs. If reusing the old studs, apply threadlock to the threads. Refer to Adhesives, Fluids, Lubricants, and Sealers for the correct part number. Tighten the studs to 10 N·m (89 lb in).

    3. Object Number: 480562 Size: SH
  3. If required, install a NEW MAP sensor seal. Apply a small drop of clean engine oil to the seal.
  4. Install the MAP sensor.

    5. Object Number: 12853 Size: SH
  5. If required, install a NEW throttle body gasket.
  6. Install the throttle body.
  7. Install the rear throttle body stud. If reusing the old stud, apply threadlock to the threads. Refer to Adhesives, Fluids, Lubricants, and Sealers for the correct part number. Tighten the stud to 9 N·m (80 lb in).

    8. Object Number: 869707 Size: SH
  8. If required, install a NEW O-ring seal to the PCV cover. Apply clean engine oil to the seal.
  9. Install the PCV valve cover.

    10. Object Number: 516797 Size: SH
  10. If required, install a NEW O-ring seal. Apply clean engine oil to the seal.
  11. Install the power brake booster vacuum fitting.

    12. Object Number: 516773 Size: SH
  12. Install a NEW O-ring seal to the fuel meter body.

    13. Object Number: 516790 Size: SH
  13. Install a NEW upper intake manifold gasket.

    14. Object Number: 516794 Size: SH
  14. Install the intake manifold - upper.
  15. If reusing the old throttle body/intake manifold studs, apply threadlock to the threads. Refer to Adhesives, Fluids, Lubricants, and Sealers for the correct part number.
  16. Install the front two throttle body studs.
  17. Install the intake manifold - upper studs and tighten to 9 N·m (80 lb in).
  18. Connect the power brake booster vacuum hose to the vacuum fitting.

    19. Object Number: 869710 Size: SH
  19. Position the engine wiring harness.
  20. Install the PCV valve hose to the valve cover and rocker cover.

    21. Object Number: 1935055 Size: SH
  21. Position the EVAP canister purge solenoid tube, and connect the tube quick connect fitting (1) to the EVAP purge solenoid valve. Refer to Plastic Collar Quick Connect Fitting Service.

    22. Object Number: 1935027 Size: SH
  22. Connect the following electrical connectors:
    23. • The EVAP canister purge solenoid valve (3)
    • The MAP sensor (2)
    • The throttle body actuator (1)

    Object Number: 1934811 Size: SH
  23. Connect the control port injector module (1).
  24. Connect the A/C compressor clutch, if equipped.
  25. Install the fuel pipes/hoses. Refer to Fuel Hose/Pipes Replacement - Engine Compartment.
  26. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
  27. Install the engine cover. Refer to Engine Cover Replacement.