Intake Manifold Replacement

Intake Manifold Replacement (5.3L)

Removal Procedure

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).

Note: The intake manifold, throttle body, fuel rail, and injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.

2. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (Service and Repair).
3. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH-48027) (Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH-48027) (Fuel Pressure Relief (Without CH-48027)).




4. Disconnect the air conditioning (A/C) compressor pressure switch electrical connector (2).
5. Remove the harness clip (1) from the cylinder head.




6. Disconnect the electrical connector (1) from the mass air flow (MAF)/intake air temperature (IAT) sensor.
7. Remove the harness clips from the fuel rail.




8. Perform the following steps in order to disconnect the fuel injector electrical connectors.

1. Mark the connectors to their corresponding injectors to ensure correct reassembly.
2. Pull the connector position assurance (CPA) retainer (2) on the connector up one click.
3. Push the tab (1) on the connector in.
4. Disconnect the fuel injector electrical connector.
5. Repeat the steps for each injector electrical connector.




9. Disconnect the following electrical connectors:

* Evaporative emission (EVAP) purge solenoid (3)
* Throttle body harness (5)
* Manifold absolute pressure (MAP) sensor (2)
* Main coil (1)
* Generator (4)

10. Remove the electrical harness clips from the fuel rail.




11. Remove the positive crankcase ventilation (PCV) hose.




12. Remove the heater water shutoff valve actuator inlet hose from the intake manifold.




13. Remove the EVAP purge solenoid vent tubes (1, 2). Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




14. Disconnect the fuel feed pipe (3) from the fuel rail (2). Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).




15. Remove the vacuum brake booster hose from the rear of the intake manifold.




16. Remove the upper engine wire harness retainer nut (1).
17. Reposition the upper engine wire harness aside.




18. Remove the intake manifold bolts.
19. Remove the intake manifold.




20. Remove the intake manifold gaskets (1) from the intake manifold.
21. Discard the old intake manifold gaskets.
22. If necessary, clean and inspect the intake manifold. Refer to Intake Manifold Cleaning and Inspection (5.3L) (Intake Manifold Cleaning and Inspection)Intake Manifold Cleaning and Inspection (6.0L) (Intake Manifold Cleaning and Inspection).

Installation Procedure




1. Install NEW intake manifold gaskets (1) to the intake manifold.




2. Install the intake manifold.
3. Apply a 5 mm (0.2 in) bead of threadlock to the threads of the intake manifold bolts. Refer to Adhesives, Fluids, Lubricants, and Sealers (Adhesives, Fluids, Lubricants, and Sealers) for the correct part number.





Caution: Refer to Fastener Caution (Fastener Caution).

4. Install the intake manifold bolts.

1. Tighten the bolts a first pass in sequence to 5 Nm (44 in. lbs.).
2. Tighten the bolts a final pass in sequence to 10 Nm (89 in. lbs.).




5. Route the electrical harness into position over the engine.
6. Install the engine harness bracket nut (1) and tighten to 10 Nm (89 in. lbs.).




7. Install the vacuum brake booster hose to the rear of the intake manifold.




8. Connect the fuel feed pipe (3) to the fuel rail (2). Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).




9. Install the EVAP purge solenoid vent tubes (1, 2). Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




10. Install the heater water shutoff valve actuator inlet hose to the intake manifold.




11. Install the PCV hose.
12. Connect the electrical harness clips to the fuel rail.




13. Connect the following electrical connectors:

* EVAP purge solenoid (3)
* Throttle body harness (5)
* MAP sensor (2)
* Main coil (1)
* Generator (4)




14. Perform the following steps in order to connect the fuel injector electrical connectors.

1. Install the connectors to their corresponding injectors to ensure correct reassembly.
2. Connect the fuel injector electrical connector.
3. Push the CPA retainer (2) on the connector in one click.
4. Repeat the steps for each injector electrical connector.

15. Install the electrical harness clips to the fuel rail.




16. Connect the A/C compressor pressure switch electrical connector (2).
17. Install the harness clip (1) to the cylinder head.




18. Connect the MAF/IAT sensor electrical connector (1).
19. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (Service and Repair).
20. Install the fuel fill cap.
21. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
22. Use the following procedure in order to inspect for leaks:

1. Turn the ignition ON, with the engine OFF, for 2 seconds.
2. Turn the ignition OFF for 10 seconds.
3. Turn the ignition ON, with the engine OFF.
4. Inspect for fuel leaks.