Wednesday, February 16, 2011

Parts location for 2004 chevy silverado 5.3

4.8L, 5.3L & 6.0L Engines

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



Click image to see an enlarged view

Fig. EVAP solenoid removal-4.8L, 5.3L and 6.0L engines

  1. Remove or disconnect the following:

    Positive Crankcase Ventilation (PCV) hose and valve
    Manifold Absolute Pressure (MAP) sensor, if required
    Engine coolant air bleed clamp and hose from the throttle body
    Knock sensor connector, if required.
    Accelerator control cable bracket and bolts, if required
    Fuel rail with injectors
    EVAP solenoid, bolt, and isolator
    Intake manifold bolts
    Intake manifold with gaskets
    Intake manifold-to-cylinder head gaskets from the manifold. Discard the intake manifold gaskets.
    Throttle body and gasket

    Click image to see an enlarged view

    Fig. Throttle body removal-4.8L, 5.3L and 6.0L engines


  2. Clean the intake manifold in solvent.
  3. Dry the intake manifold with compressed air.
  4. Inspect the throttle body and wire harness studs and stud inserts for looseness or damaged threads.
  5. Inspect the fuel rail bolt inserts for looseness or damaged threads.
  6. Inspect the intake manifold vacuum passages for debris or restrictions.
  7. Inspect for damaged or broken vacuum fittings, damaged MAP sensor mounting bore, or broken MAP sensor retaining tabs.
  8. Inspect the composite intake manifold assembly for cracks or other damage.
  9. Inspect the areas between the intake runners. Inspect all the gasket sealing surfaces for damage.
  10. Inspect the fuel injector bores for excessive scoring or damage. Inspect the intake manifold cylinder head deck for warpage.
  11. Locate a straight edge across the intake manifold cylinder head deck surface. Position the straight edge across a minimum of two runner port openings.
  12. Insert a feeler gauge between the intake manifold and the straight edge. A intake manifold with warpage in excess of 0.118 in. (3mm) over a 7.87 in. (200mm) area is warped and should be replaced.

To install:

  1. Install or connect the following:

    MAP sensor
    EVAP solenoid, bolt, and isolator. Tighten the bolt to 89 inch lbs. (10 Nm).
    NEW intake manifold-to-cylinder head gaskets
    Intake manifold

  2. Apply a 0.20 in. (5mm) band of threadlock GM P/N 12345382 or equivalent to the threads of the intake manifold bolts.

    Click image to see an enlarged view

    Fig. Lower intake manifold bolt tightening sequence-4.8L, 5.3L and 6.0L engines



    Intake manifold bolts. Tighten intake manifold bolts first pass in sequence to 44 inch lbs. (5 Nm). Tighten intake manifold bolts final pass in sequence to 89 inch lbs. (10 Nm).
    PCV valve and hose
    Coolant air bleed hose and clamp onto the throttle body
    Accelerator control cable bracket and bolts. Tighten the bolts to 89 inch lbs. (10 Nm).



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

  1. Remove or disconnect the following:

    Positive Crankcase Ventilation (PCV) hose and valve
    Manifold Absolute Pressure (MAP) sensor, if required
    Engine coolant air bleed clamp and hose from the throttle body
    Knock sensor connector, if required.
    Accelerator control cable bracket and bolts, if required
    Fuel rail with injectors

    Click image to see an enlarged view

    Fig. EVAP solenoid removal-4.8L, 5.3L and 6.0L engines

    EVAP solenoid, bolt, and isolator
    Intake manifold bolts
    Intake manifold with gaskets
    Intake manifold-to-cylinder head gaskets from the manifold. Discard the intake manifold gaskets.

    Click image to see an enlarged view

    Fig. Throttle body removal-4.8L, 5.3L and 6.0L engines

    Throttle body and gasket

  2. Clean the intake manifold in solvent.
  3. Dry the intake manifold with compressed air.
  4. Inspect the throttle body and wire harness studs and stud inserts for looseness or damaged threads.
  5. Inspect the fuel rail bolt inserts for looseness or damaged threads.
  6. Inspect the intake manifold vacuum passages for debris or restrictions.
  7. Inspect for damaged or broken vacuum fittings, damaged MAP sensor mounting bore, or broken MAP sensor retaining tabs.
  8. Inspect the composite intake manifold assembly for cracks or other damage.
  9. Inspect the areas between the intake runners. Inspect all the gasket sealing surfaces for damage.
  10. Inspect the fuel injector bores for excessive scoring or damage. Inspect the intake manifold cylinder head deck for warpage.
  11. Locate a straight edge across the intake manifold cylinder head deck surface. Position the straight edge across a minimum of two runner port openings.
  12. Insert a feeler gauge between the intake manifold and the straight edge. A intake manifold with warpage in excess of 0.118 in. (3mm) over a 7.87 in. (200mm) area is warped and should be replaced.

To install:

  1. Install or connect the following:

    MAP sensor
    EVAP solenoid, bolt, and isolator. Tighten the bolt to 89 inch lbs. (10 Nm).
    NEW intake manifold-to-cylinder head gaskets
    Intake manifold

  2. Apply a 0.20 in. (5mm) band of threadlock GM P/N 12345382 or equivalent to the threads of the intake manifold bolts.

    Intake manifold bolts. Tighten intake manifold bolts first pass in sequence to 44 inch lbs. (5 Nm). Tighten intake manifold bolts final pass in sequence to 89 inch lbs. (10 Nm).

    Click image to see an enlarged view

    Fig. Lower intake manifold bolt tightening sequence-4.8L, 5.3L and 6.0L engines

    PCV valve and hose
    Coolant air bleed hose and clamp onto the throttle body
    Accelerator control cable bracket and bolts. Tighten the bolts to 89 inch lbs. (10 Nm).



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

  1. Partially drain the engine coolant.
  2. Remove or disconnect the following:

    Air cleaner outlet duct
    Engine sight shield
    Throttle actuator motor electrical connector
    Coolant air bleed hose from the throttle body
    Throttle body
    Fuel rail with injectors
    Manifold Absolute Pressure (MAP) sensor, if required
    Knock sensor connector
    Vacuum brake booster hose from the rear of the intake manifold
    Positive Crankcase Ventilation (PCV) hose and valve
    EVAP solenoid, bolt, and isolator

    Click image to see an enlarged view

    Fig. EVAP solenoid removal-4.8L, 5.3L and 6.0L engines

    Intake manifold bolts
    Intake manifold with gaskets
    Intake manifold-to-cylinder head gaskets from the manifold. Discard the intake manifold gaskets.
    Throttle body and gasket

  3. Clean the intake manifold in solvent.
  4. Dry the intake manifold with compressed air.
  5. Inspect all components for damage, and replace the necessary parts.
  6. Locate a straight edge across the intake manifold cylinder head deck surface. Position the straight edge across a minimum of two runner port openings.
  7. Insert a feeler gauge between the intake manifold and the straight edge. An intake manifold with warpage in excess of 0.118 in. (3mm) over a 7.87 in. (200mm) area is warped and should be replaced.

To install:

  1. Install or connect the following:

    MAP sensor
    EVAP solenoid, bolt, and isolator. Tighten the bolt to 89 inch lbs. (10 Nm).
    NEW intake manifold-to-cylinder head gaskets
    Intake manifold. Apply a 0.20 in. (5mm) band of threadlock GM P/N 12345382 or equivalent to the threads of the intake manifold bolts.
    Intake manifold bolts. Tighten intake manifold bolts, in sequence, to 44 inch lbs. (5 Nm). Then, tighten the bolts, in sequence, to 89 inch lbs. (10 Nm).

    Click image to see an enlarged view

    Fig. Lower intake manifold bolt tightening sequence-4.8L, 5.3L and 6.0L engines

    Vacuum brake booster hose from the rear of the intake manifold
    Knock sensor connector
    Manifold Absolute Pressure (MAP) sensor, if required
    Air cleaner outlet duct
    Fuel rail with injectors
    Throttle body
    Coolant air bleed hose to the throttle body
    Throttle actuator motor electrical connector
    Engine sight shield



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

  1. Remove or disconnect the following:

    PCV hose and valve
    MAP sensor, if required
    Engine coolant air bleed clamp and hose from the throttle body
    Accelerator control cable bracket and bolts, if required

    Click image to see an enlarged view

    Fig. EVAP solenoid removal-4.8L, 5.3L, 6.0L

    EVAP solenoid, bolt, and isolator
    Intake manifold bolts
    Intake manifold with gaskets
    Intake manifold-to-cylinder head gaskets from the manifold. Discard the intake manifold gaskets.
    Fuel rail with injectors

    Click image to see an enlarged view

    Fig. Throttle body removal-4.8L, 5.3L, 6.0L

    Throttle body and gasket

  2. Clean the intake manifold in solvent.
  3. Dry the intake manifold with compressed air.
  4. Inspect the throttle body studs and stud inserts for looseness or damaged threads.
  5. Inspect the wire harness stud and stud insert for looseness or damaged threads.
  6. Inspect the fuel rail bolt inserts for looseness or damaged threads.
  7. Inspect the intake manifold vacuum passages for debris or restrictions.
  8. Inspect for damaged or broken vacuum fittings, damaged MAP sensor mounting bore, or broken MAP sensor retaining tabs.
  9. Inspect the composite intake manifold assembly for cracks or other damage.
  10. Inspect the areas between the intake runners. Inspect all the gasket sealing surfaces for damage.
  11. Inspect the fuel injector bores for excessive scoring or damage. Inspect the intake manifold cylinder head deck for warpage.
  12. Locate a straight edge across the intake manifold cylinder head deck surface. Position the straight edge across a minimum of two runner port openings.
  13. Insert a feeler gauge between the intake manifold and the straight edge. A intake manifold with warpage in excess of 3 mm (0.118 in) over a 200 mm (7.87 in) area is warped and should be replaced.

To install:


NOTE
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.

  1. Install or connect the following:

    MAP sensor
    EVAP solenoid, bolt, and isolator. Tighten the EVAP solenoid bolt to 10 Nm (89 inch lbs.).
    NEW intake manifold-to-cylinder head gaskets
    Intake manifold. Apply a 5 mm (0.20 in) band of threadlock GM P/N 12345382 or equivalent to the threads of the intake manifold bolts.
    Intake manifold bolts. Tighten intake manifold bolts first pass in sequence to 5 Nm (44 inch lbs.). Tighten intake manifold bolts final pass in sequence to 10 Nm (89 inch lbs.).

    Click image to see an enlarged view

    Fig. Lower intake manifold bolt tightening sequence-4.8L, 5.3L and 6.0L engines

    PCV valve and hose. Install the engine coolant air bleed hose and clamp onto the throttle body.
    Accelerator control cable bracket and bolts, if applicable. Tighten the accelerator control cable bracket bolts to 10 Nm (89 inch lbs.).



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

  1. Remove or disconnect the following:

    PCV hose and valve
    MAP sensor, if required
    Engine coolant air bleed clamp and hose from the throttle body
    Accelerator control cable bracket and bolts, if required

    Click image to see an enlarged view

    Fig. EVAP solenoid removal-4.8L, 5.3L, 6.0L

    EVAP solenoid, bolt, and isolator
    Intake manifold bolts
    Intake manifold with gaskets
    Intake manifold-to-cylinder head gaskets from the manifold. Discard the intake manifold gaskets.
    Fuel rail with injectors

    Click image to see an enlarged view

    Fig. Throttle body removal-4.8L, 5.3L, 6.0L

    Throttle body and gasket

  2. Clean the intake manifold in solvent.
  3. Dry the intake manifold with compressed air.
  4. Inspect the throttle body studs and stud inserts for looseness or damaged threads.
  5. Inspect the wire harness stud and stud insert for looseness or damaged threads.
  6. Inspect the fuel rail bolt inserts for looseness or damaged threads.
  7. Inspect the intake manifold vacuum passages for debris or restrictions.
  8. Inspect for damaged or broken vacuum fittings, damaged MAP sensor mounting bore, or broken MAP sensor retaining tabs.
  9. Inspect the composite intake manifold assembly for cracks or other damage.
  10. Inspect the areas between the intake runners. Inspect all the gasket sealing surfaces for damage.
  11. Inspect the fuel injector bores for excessive scoring or damage. Inspect the intake manifold cylinder head deck for warpage.
  12. Locate a straight edge across the intake manifold cylinder head deck surface. Position the straight edge across a minimum of two runner port openings.
  13. Insert a feeler gauge between the intake manifold and the straight edge. A intake manifold with warpage in excess of 3 mm (0.118 in) over a 200 mm (7.87 in) area is warped and should be replaced.

To install:


NOTE
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.

  1. Install or connect the following:

    MAP sensor
    EVAP solenoid, bolt, and isolator. Tighten the EVAP solenoid bolt to 10 Nm (89 inch lbs.).
    NEW intake manifold-to-cylinder head gaskets
    Intake manifold. Apply a 5 mm (0.20 in) band of threadlock GM P/N 12345382 or equivalent to the threads of the intake manifold bolts.
    Intake manifold bolts. Tighten intake manifold bolts first pass in sequence to 5 Nm (44 inch lbs.). Tighten intake manifold bolts final pass in sequence to 10 Nm (89 inch lbs.).

    Click image to see an enlarged view

    Fig. Lower intake manifold bolt tightening sequence-4.8L, 5.3L and 6.0L engines

    PCV valve and hose. Install the engine coolant air bleed hose and clamp onto the throttle body.
    Accelerator control cable bracket and bolts, if applicable. Tighten the accelerator control cable bracket bolts to 10 Nm (89 inch lbs.).



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

  1. Remove or disconnect the following:

    Alternator
    Positive Crankcase Ventilation (PCV) hose and valve
    Manifold Absolute Pressure (MAP) sensor, if required
    Engine coolant air bleed clamp and hose from the throttle body
    Knock sensor connector, if required.
    Accelerator control cable bracket and bolts, if required
    Fuel rail with injectors, if required
    EVAP solenoid, bolt, and isolator
    Any additional engine harness attachment points and set aside
    Intake manifold bolts
    Intake manifold with gaskets
    Intake manifold-to-cylinder head gaskets from the manifold. Discard the intake manifold gaskets.

    Click image to see an enlarged view

    Fig. Always use new gaskets-4.8L, 5.3L and 6.0L engines


  2. Clean the intake manifold in solvent.
  3. Dry the intake manifold with compressed air.
  4. Inspect the intake manifold vacuum passages for debris or restrictions.
  5. Inspect for damaged or broken vacuum fittings, damaged MAP sensor mounting bore, or broken MAP sensor retaining tabs.
  6. Inspect the composite intake manifold assembly for cracks or other damage.
  7. Inspect the areas between the intake runners. Inspect all the gasket sealing surfaces for damage.
  8. Inspect the fuel injector bores for excessive scoring or damage. Inspect the intake manifold cylinder head deck for warpage.
  9. Locate a straight edge across the intake manifold cylinder head deck surface. Position the straight edge across a minimum of two runner port openings.
  10. Insert a feeler gauge between the intake manifold and the straight edge. A intake manifold with warpage in excess of 0.118 in. (3mm) over a 7.87 in. (200mm) area is warped and should be replaced.

To install:

  1. Install or connect the following:

    MAP sensor
    EVAP solenoid, bolt, and isolator. Tighten the bolt to 89 inch lbs. (10 Nm).
    NEW intake manifold-to-cylinder head gaskets
    Intake manifold

  2. Apply a 0.20 in. (5mm) band of threadlock GM P/N 12345382 or equivalent to the threads of the intake manifold bolts.

    Intake manifold bolts. Tighten intake manifold bolts first pass in sequence to 44 inch lbs. (5 Nm). Tighten intake manifold bolts final pass in sequence to 89 inch lbs. (10 Nm).

    Click image to see an enlarged view

    Fig. Lower intake manifold bolt tightening sequence-4.8L, 5.3L and 6.0L engines

    PCV valve and hose
    Coolant air bleed hose and clamp onto the throttle body
    Accelerator control cable bracket and bolts. Tighten the bolts to 89 inch lbs. (10 Nm).
    Alternator


4.8L, 5.3L, 6.0L & 6.2L Engines

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

  1. Remove or disconnect the following:

    Alternator
    Positive Crankcase Ventilation (PCV) hose and valve
    Manifold Absolute Pressure (MAP) sensor, if required
    Engine coolant air bleed clamp and hose from the throttle body
    Knock sensor connector, if required.
    Accelerator control cable bracket and bolts, if required
    Fuel rail with injectors, if required
    EVAP solenoid, bolt, and isolator
    Any additional engine harness attachment points and set aside
    Intake manifold bolts
    Intake manifold with gaskets
    Intake manifold-to-cylinder head gaskets from the manifold. Discard the intake manifold gaskets.

    Click image to see an enlarged view

    Fig. Always use new gaskets-4.8L, 5.3L, 6.0L and 6.2L engines


  2. Clean the intake manifold in solvent.
  3. Dry the intake manifold with compressed air.
  4. Inspect the intake manifold vacuum passages for debris or restrictions.
  5. Inspect for damaged or broken vacuum fittings, damaged MAP sensor mounting bore, or broken MAP sensor retaining tabs.
  6. Inspect the composite intake manifold assembly for cracks or other damage.
  7. Inspect the areas between the intake runners. Inspect all the gasket sealing surfaces for damage.
  8. Inspect the fuel injector bores for excessive scoring or damage. Inspect the intake manifold cylinder head deck for warpage.
  9. Locate a straight edge across the intake manifold cylinder head deck surface. Position the straight edge across a minimum of two runner port openings.
  10. Insert a feeler gauge between the intake manifold and the straight edge. A intake manifold with warpage in excess of 0.118 in. (3mm) over a 7.87 in. (200mm) area is warped and should be replaced.

To install:

  1. Install or connect the following:

    MAP sensor
    EVAP solenoid, bolt, and isolator. Tighten the bolt to 89 inch lbs. (10 Nm).
    NEW intake manifold-to-cylinder head gaskets
    Intake manifold

  2. Apply a 0.20 in. (5mm) band of threadlock GM P/N 12345382 or equivalent to the threads of the intake manifold bolts.

    Intake manifold bolts. Tighten intake manifold bolts first pass in sequence to 44 inch lbs. (5 Nm). Tighten intake manifold bolts final pass in sequence to 89 inch lbs. (10 Nm).

    Click image to see an enlarged view

    Fig. Lower intake manifold bolt tightening sequence-4.8L, 5.3L, 6.0L and 6.2L engines

    PCV valve and hose
    Coolant air bleed hose and clamp onto the throttle body
    Accelerator control cable bracket and bolts. Tighten the bolts to 89 inch lbs. (10 Nm).
    Alternator




Fuel tank removal:---
  1. Remove the fuel tank.
  2. Disconnect fuel and evaporative emission (EVAP) lines from the fuel tank module.
    WARNING
    Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage tool Joints. Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation.

  3. Remove the cam lock ring using tool J45722 or equivalent.
  4. Carefully lift the fuel tank module from the fuel tank, enough to access the quick connect fittings below the module cover.
  5. Squeeze the quick connect fittings in order to disengage them from the module cover.
  6. Remove the fuel tank module from the fuel tank.
  7. Remove and discard the fuel tank module seal.
    NOTE
    Important: Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped. Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring.


    NOTE
    Check the lock ring for flatness by placing the lock ring on a flat surface and measuring the clearance between the lock ring and the flat surface using a feeler gauge at 7 points. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.


To install:

  1. Install the NEW fuel tank module seal onto the fuel tank.
  2. Position the fuel tank module part way into the fuel tank.
  3. Connect the quick connect fittings to the module cover.
  4. Install the fuel tank module into the fuel tank.
  5. Place the cam lock ring into position.
    NOTE
    Important: Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction.

  6. Rotate the cam lock ring clockwise using tool J45722 or equivalent until fully seated.
  7. Connect the fuel and EVAP lines to the fuel tank module.
  8. Install the fuel tank.
  1. Remove the sending unit.
  2. Disconnect the fuel pump electrical connector.
  3. Remove the fuel lever sensor electrical connector retaining clip.
  4. Disconnect the fuel level sensor electrical connector.
  5. Remove the fuel level sensor retaining clip.
  6. Remove the fuel level sensor (1).

    Click image to see an enlarged view

    Fig. The fuel level sensor is part of the fuel pump assembly-typical


To install:

  1. Install the fuel level sensor (1).
  2. Install the fuel level sensor retaining clip.
  3. Connect the fuel level sensor electrical connector.
  4. Install the fuel lever sensor electrical connector retaining clip.
  5. Connect the fuel pump electrical connector.
  6. Install the sending unit.

PART NUMBER 3 IS SENSOR:--
image



Click image to see an enlarged view

Fig. EVAP Purge valve solenoid (3) mounting bolt (2) and insulator (1) on 2000-2005

5.3L, 6.0L Engines.


Manifold Absolute Pressure Sensor

Click image to see an enlarged view

Fig. MAP sensor location on 2000-2005 5.3L, 6.0L Engines.