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Home >> Chevy Truck >> 1999 >> K 2500 Suburban 4WD V8-5.7L VIN R >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Intake Manifold >> Service and Repair >> Lower Intake Manifold Replacement

Lower Intake Manifold Replacement





Intake Manifold Replacement (Lower)

Removal Procedure

1. Disconnect the battery negative cable.
2. Drain the engine coolant. Refer to Cooling System Draining and Filling Service and Repair.
3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement Service and Repair.






4. Remove the following coolant hoses:
5. Upper radiator hose. Refer to Radiator Hose Replacement Service and Repair.
6. Both heater hoses. Refer to Heater Hoses Replacement Service and Repair.
7. Water pump inlet hose. Refer to Heater Water Bypass Valve Replacement HVAC System - Manual.
8. Disconnect all electrical connectors and secure out of the way.
9. Remove the distributor. Refer to Distributor Replacement Service and Repair.
10. Use a twisting motion to remove the vacuum brake booster hose, if equipped.
11. Disconnect the accelerator control cable and the cruise control cable, if equipped. Refer to Accelerator Controls Cable Replacement Service and Repair.
12. Remove the drive belt. Refer to Drive Belt Replacement Service and Repair.

Important: It is not necessary to discharge the A/C refrigerant.

Remove the air conditioning (A/C) compressor, if equipped, and set the A/C compressor aside. Refer to Air Conditioning Compressor Replacement Service and Repair.






13. Remove the PCV valve.
14. Disconnect the exhaust gas recirculation (EGR) pipe from the bracket and the front of the intake manifold. Refer to Secondary Air Injection Check Valve and Check Valve Pipe Replacement Service and Repair.
15. Disconnect the fuel pipes from the rear of the intake manifold. Refer to Fuel Hose/Pipe Assembly Replacement Service and Repair.
16. Disconnect the electrical connector from the power steering pump.






17. Remove the power steering bracket using the following procedure:
- Remove the power steering pump. Refer to Power Steering Pump Replacement Power Steering Pump Replacement.
- Remove the nut, then the bolts.
- Remove two nuts from the back of the power steering pump.
- Slide the power steering bracket forward, with the power steering pump still attached.
18. Disconnect the wiring bracket from the rear of the right cylinder head.
19. Remove the valve rocker arm covers. Refer to Valve Rocker Arm Cover Replacement Service and Repair.
20. Remove the intake manifold. Refer to Intake Manifold Removal 12. Intake Manifold Removal.
21. Clean all surfaces. Refer to Intake Manifold Clean and Inspect 54. Intake Manifold Clean and Inspect.

Installation Procedure

1. Install the intake manifold. Refer to Intake Manifold Installation 76. Intake Manifold Installation.
2. Install the valve rocker arm covers Refer to Valve Rocker Arm Cover Installation (Right) 79. Valve Rocker Arm Cover Installation - Right and Valve Rocker Arm Cover Installation (Left) 78. Valve Rocker Arm Cover Installation - Left.






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.

3. Install the power steering bracket using the following procedure:
- Install the power steering bracket onto the stud.
- Install the nut onto the stud finger tight.
- Install the three bolts finger tight.
- Install the two nuts to the back of the power steering pump.

Tighten
Tighten the nuts and the bolts to 41 Nm (30 lb ft).

- Install the power steering pump. Refer to Power Steering Pump Replacement Power Steering Pump Replacement.
- Connect the electrical connector to the power steering pump.
- Connect the fuel pipes to the rear of the intake manifold. Refer to Fuel Hose/Pipe Assembly Replacement Service and Repair.
- Connect the wiring bracket to the rear of the right cylinder head.






4. Install the PCV valve.
5. Connect the exhaust gas recirculation (EGR) pipe to the bracket and the front of the intake manifold. Refer to Secondary Air Injection Check Valve and Check Valve Pipe Replacement Service and Repair.
6. Use a twisting motion to install the vacuum brake booster hose, if equipped.
7. Install AIR check valve (crossover) pipe, if equipped. Refer to Secondary Air Injection Check Valve and Check Valve Pipe Replacement Service and Repair.






8. Install the air conditioning (A/C) compressor onto the power steering bracket.
9. Install the A/C compressor bolts.

Tighten
Tighten the bolts to 50 Nm (37 lb ft).

10. Install the drive belt. Refer to Drive Belt Replacement Service and Repair.
11. Connect the accelerator control cable and the cruise control cable, if equipped. Refer to Accelerator Controls Cable Replacement Service and Repair.
12. Install the distributor. Refer to Distributor Replacement Service and Repair.
13. Connect all electrical connectors.






14. Install the following coolant hoses.
- Upper radiator hose. Refer to Radiator Hose Replacement Service and Repair.
- Both heater hoses. Refer to Heater Hoses Replacement Service and Repair.
- Water pump inlet. Refer to Heater Water Bypass Valve Replacement Heating and Ventilation.
- Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement Service and Repair.
- Fill the cooling system with coolant. Refer to Cooling System Draining and Filling Service and Repair.
- Connect the battery negative cable.
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