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Eric, Automotive Repair Shop Manager
Category: Chevy
Satisfied Customers: 24294
Experience:  20+ yrs. experience as repair shop manager and technician.
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HOW DIFFICULT WOULD IT BE TO CHANGE THE INTAKE MANIFOLD GASKET

Resolved Question:

HOW DIFFICULT WOULD IT BE TO CHANGE THE INTAKE MANIFOLD GASKET ON MY 1999 3 QUARTER TON 4X4 CHEVY SUBURBAN WITH A 454 VORTEC ENGINE? WHERE COULD A FIND THIS PROCEDURE?
Submitted: 4 years ago.
Category: Chevy
Expert:  Eric replied 4 years ago.

Hi,

 

This is a job that can be done at home. Depending upon your mechanical skills, it will take somewhere between 2 1/2 to 4hrs.

 

Below are directions:

 

UPPER INTAKE:

 

  1. Remove or disconnect the following:
    NOTE Note the location of the manifold bolts and studs before removal for reassembly in their original positions.

    NOTE Do not disassemble the Central Sequential Fuel Injection (CSFI) unit.


  2. Negative battery cable
  3. Engine cover
  4. Air cleaner intake duct
  5. Coolant reservoir
  6. Wiring harness connectors and brackets
  7. Throttle linkage and bracket from the upper intake manifold
  8. Cruise control cable, if equipped
  9. Fuel lines and the bracket from the rear of the intake manifold
  10. Positive Crankcase Ventilation (PCV) valve and hoses
  11. Ignition coil and bracket
  12. Purge solenoid and bracket


    Intake manifold bolts and studs


    Upper intake manifold

LOWER INTAKE:

  1. Distributor (SEE BOTTOM for special directions)
  2. Upper radiator hose from the thermostat housing
  3. Heater hose from the lower intake manifold
  4. Coolant bypass hose
  5. Exhaust Gas Recirculation (EGR) valve
  6. Fuel pressure and return lines from the lower intake manifold
  7. Wiring harnesses and brackets from the lower manifold
  8. Left side valve cover
  9. Transmission oil level indicator and tube, if equipped
  10. EGR tube, clamp and bolt
  11. Positive Crankcase Ventilation (PCV) valve and hoses
  12. Air conditioning compressor and bracket, but do not disconnect the lines
  13. Loosen the compressor mounting bracket and slide it forward, but do not remove it.

  14. Power brake vacuum tube
  15. Lower intake manifold bolts and lower intake manifold

 

To install:

  1. Clean all gasket surfaces completely.
  2. Install the intake manifold gaskets with the port blocking plates facing the rear. Factory gaskets should have the words This Side Up visible.
  3. Apply gasket sealer to the front and rear sealing surfaces of the engine block. Extend the sealer approximately 1 / 2 inch (13mm) onto the heads.
  4. Install the lower intake manifold.
  5. Apply sealer to the lower intake manifold bolts prior to installation.
  6. On the 7.4L engine, torque the bolts to 30 ft. lbs. (40 Nm) in the sequence shown.



  7. Click image to see an enlarged view

    Fig. Upper and lower intake manifold bolt tightening sequence-7.4L engines

  8. Install or connect the following:
    WARNING When installing the upper intake manifold be careful not to pinch the injector wires between the upper and lower intake manifolds.


  9. Power brake vacuum tube
  10. PCV valve and hose
  11. EGR tube, clamp and bolt
  12. Transmission oil level indicator and tube, if equipped
  13. Left side valve cover
  14. Wiring harnesses and brackets to the lower manifold
  15. Fuel pressure and return lines to the lower intake manifold
  16. EGR valve
  17. Coolant bypass hose
  18. Heater hose to the lower intake manifold
  19. Upper radiator hose to the thermostat housing
  20. Air conditioning compressor and bracket
  21. Distributor
  22. Upper intake manifold gasket
  23. Upper intake manifold


    Upper intake manifold mounting bolts/studs, torque in a crisscross pattern as follows:
    1. Step 1: Torque to 44 inch lbs. (5 Nm).
    2. Step 2: Torque to 83 inch lbs. (10 Nm).

    3. Purge solenoid and bracket
    4. PCV hose
    5. Fuel lines and the bracket at the rear of the intake manifold
    6. Ignition coil and bracket
    7. Throttle linkage and bracket to the upper intake manifold
    8. Throttle linkage cable
    9. Cruise control cable, if equipped
    10. Wiring harness connectors and brackets
    11. Air cleaner intake duct
    12. Coolant recovery reservoir and the engine cover
    13. Negative battery cable

  24. Start the vehicle and verify that there are no leaks

 

 

DISTRIBUTOR:

 

  • Remove or disconnect the following:

  • Negative battery cable
  • Spark plug wires and the coil leads from the distributor
  • Electrical connector at the base of the distributor
  • Distributor cap
  • Matchmark the rotor-to-housing and housing-to-engine block positions so that they can be matched during installation.

  • Distributor hold-down bolt
  • Distributor from the engine
  •  

     

    Timing Not Disturbed installation:

    1. Install or connect the following:

    2. Distributor, aligning the matchmarks properly
    3. Distributor hold-down bolt
    4. Distributor cap
    5. Electrical connector at the base of the distributor
    6. Spark plug wires and coil leads
    7. Negative battery cable
    Eric, Automotive Repair Shop Manager
    Category: Chevy
    Satisfied Customers: 24294
    Experience: 20+ yrs. experience as repair shop manager and technician.
    Eric and 6 other Chevy Specialists are ready to help you

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