Q: How to replace the intake manifold on the L92 - First Design on 2007 GMC Sierra 3500 Classic?
A: To remove Intake Manifold (500) on l92- first design begin by removing the air cleaner outlet duct, generator as well as engine harness retainer nut for then to serve as you then detach the engine harness retainer from the stud and locator. Remove the engine harness electrical connectors for evap canister purge solenoid , manifold absolute pressure (MAP) sensor , ignition coil harness , left side fuel injectors , throttle actuator , engine coolant temperature (ECT) sensor , and right side fuel injectors . Disconnect the clips of the engine harness (4, 6, 1) and collect the branches of the harness to bundle them so as to avoid interfering with other components. Loosen the brake booster vacuum hose clamp, disconnect the vacuum hose from the booster fitting, and disconnect the evap canister purge tube, as well as the fuel feed line. Loosen and remove the Intake Manifold, discard Intake Manifold gaskets (514), and place the cover on the passages at the cylinder head to avoid entraining debris. If you are replacing the manifold, put it on a clean surface, reinstall the brake booster vacuum hose clamp and pull the vacuum hose from the manifold nipple. Remove the upper Intake Manifold cover nut and cover, MAP Sensor retainer and sensor, evap tube, throttle body and Fuel Rail are to be removed while lifting evenly to prevent injector damage. For installation, in case the manifold was replaced, fit the brake booster vacuum hose nipple to the manifold, and add new Fuel Injector mean o-ring seals, lubing them with clean engine oil then fit the Fuel Rail, and bolt to 10 n.m (89 lb in). Replace Throttle Body with new one, secure with bolts/nuts to the same torque and replace Throttle Body gassomat. Reattach the evap tube and purge solenoid, and lubricate the MAP Sensor seal and install the MAP Sensor and retainer. Replace with upper Intake Manifold cover and the nut, attach the brake booster vacuum hose and fix it. Put new Intake Manifold gaskets (514) onto the manifold, also remove the cylinder head passage covers, and fit manifold, tighten bolts (512) temporarily to 5 n.m (44 lb in); then 10 n.m (89 lb in) in the order noted. If the vacuum hose is reconnected along with the pcv hose, fuel feed line, and the evap canister purge tube, and then secure the brake booster vacuum hose to the booster fitting. Open the engine harness and disconnect the branches while reconnect the ect sensor, secure the harness clips to the generator bracket and ignition coil bracket. Solder the electrical connectors to the right and left side fuel injectors, turn actuator and ignition coil harness, and follow with installation of the cpa retainers. Last, reconnect the MAP Sensor and evap canister purge solenoid and tighten the engine harness retainer nut to 5 n.m (44 lb in), replace the generator, and complete by attaching the air cleaner outlet duct.