GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2002 🢒 Chevy C Cab/Chassis HD (GMT 400) 🢒 Engine 🢒 Engine Mechanical - 6.5L 🢒 Lower Intake Manifold Replacement

Removal Procedure

    Object Number: 309354 Size: SH
  1. Disconnect both the battery negative cables from the batteries. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Remove the upper intake manifold from the lower intake manifold. Refer to Upper Intake Manifold Replacement .

    3. Object Number: 59759 Size: SH
  3. Remove the fuel filter from the lower intake manifold and position to the side.

    4. Object Number: 26781 Size: SH
  4. Remove the glow plug relay from the lower intake manifold.

    5. Object Number: 309356 Size: SH
  5. Remove the nuts retaining the heater hose bracket.
  6. Remove the heater hoses and bracket.

    7. Object Number: 309350 Size: SH
  7. Remove the ground straps from the right rear corner of the lower intake manifold.

    8. Object Number: 309340 Size: SH
  8. Disconnect the engine wiring harness (if needed) and secure out of the way.

    9. Object Number: 59835 Size: SH
  9. Remove the lower intake manifold bolts from the cylinder head.
  10. Remove the lower intake manifold and the gasket from the cylinder heads.
  11. Clean and check the sealing surfaces of the cylinder head and the engine block.

Installation Procedure

    Object Number: 59835 Size: SH
  1. Install the intake manifold and gaskets.

    2. Object Number: 59761 Size: SH

    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.

  2. Install the intake manifold bolts/studs and fuel line clips.
    3. • Use Teflon sealer to seal the four bolts, numbers 9, 11, 13, and 15 that are exposed to the crankcase.
    • Apply threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolts and the studs that are not numbered 9, 11, 13, or 15.

    Tighten
    Tighten the intake manifold bolts/studs, in sequence, to 42 N·m (31 lb ft).


    Object Number: 309350 Size: SH
  3. Install the grounds straps to the right rear of the cylinder head.
  4. Install the ground strap nuts.

    5. Tighten
    Tighten the ground strap nuts to 25 N·m (18 lb ft).

  5. Install the glow plug relay to the lower intake manifold. Refer to Glow Plug Relay Replacement in Engine Controls-6.5L-L65.

    6. Object Number: 309340 Size: SH
  6. Install the engine wiring harness (right side).

    7. Object Number: 309356 Size: SH
  7. Install the heater hose bracket and nuts.

    8. Tighten
    Tighten the heater hose bracket nuts to 30 N·m (522 lb ft).


    Object Number: 59759 Size: SH
  8. Install the fuel filter to the lower intake manifold.
  9. Install the fuel filter bolts.

    10. Tighten
    Tighten the fuel filter bolts to 42 N·m (31 lb ft).

  10. Install the upper intake manifold to the lower intake. Refer to Upper Intake Manifold Replacement .
  11. Connect both the battery negative cables to the batteries. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.