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GMC Yukon XLModel years 2000–2006

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EngineModel years 1999–2005ManufacturerTrade technical source

Intake manifold gasket leak (cold idle misfire, lean codes)

As reported by MOTOR Magazine from GM PIP3232C: 1999-2005 GMC Savana, Sierra and Yukon models and other listed GM trucks; the article concerns the 5.3L Vortec with plastic intake manifold

FaultCrate・Intake manifold gasket leak (cold idle misfire, lean codes)

The bulletin describes a cold engine idle misfire with DTCs P0171, P0174 or P0300.

The bulletin states the intake gasket seals may leak around the intake ports, causing the lean condition.

Leaks typically occur when the engine is cold and may subside as it warms.

How to tell

What to do

  1. The seals may leak around the bottom side of the port, which makes the vacuum leak hard to detect.
  2. Lower-than-normal MAF readings may be seen if the intake seals are leaking.
  3. An intake manifold with warpage in excess of 3mm (.118 in.) over a 200mm (7.87-in.) area must be replaced.
  4. Measure the intake manifold for warpage across two runner ports only.
  5. Only the current teal green gaskets should be used; the old gaskets were orange.
  6. The intake bolts must be replaced and not reused.
  7. Replace the upper manifold gasket with the teal-green gasket.
  8. A new gasket made of FNK material (GM SPO p/n 89017589) has been released; the new gasket material is teal green, and the original gaskets are orange.
  9. Use only the 89017589 gasket (teal green) for repairs on the L59 engine.

Part numbers printed in the document

The numbers are as the document prints them. The name and the replacing number are what the pages of GMPartsGiant, a reseller of genuine parts and not GM, state. Aftermarket equivalents are not checked here (the links only search by number). Confirm the fit for the vehicle (VIN) before ordering.

Caution

  • Do not measure the intake manifold across all four intake runner ports.
  • Do not replace the upper intake manifold gasket with an orange gasket.

Applies to

  • MOTOR reports the GM bulletin lists 1999-2005 GMC Savana, Sierra and Yukon models among affected vehicles.
  • The row is for 2002-2004 Silverado, Suburban, Tahoe, Sierra, Yukon/XL and Escalade EXT with rough idle, misfire and MIL with DTC P0300.
  • This article applies specifically to the 5.3L L59 (E85 capable), as well as the other Gen 3 and Gen 4 engines.
See the evidence (3 documents, 17 passages)
DocumentPublisherDate
[1]Trouble Shooter: Take a Deep Breath (lean misfire, 5.3L Vortec) ↗
Trade technical sourceMOTOR Magazine
2017-02-06
[2]GM TechLink, January 2006 ↗
ManufacturerGeneral Motors
2006-01-01
[3]GM TechLink, May 2005 ↗
ManufacturerGeneral Motors
2005-05-01

  • Applies toMOTOR reports the GM bulletin lists 1999-2005 GMC Savana, Sierra and Yukon models among affected vehicles.

    Affected vehicles include 2002-05 Cadillac Escalades, 1999-2005 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe and Trailblazer models, 1999-2005 GMC Savana, Sierra and Yukon models, and 2003-05 HUMMER H2s.— [1]

  • First signsThe bulletin describes a cold engine idle misfire with DTCs P0171, P0174 or P0300.

    It describes a cold engine idle misfire, with DTCs P0171 P0174 or P0300.— [1]

  • Why it happensThe bulletin states the intake gasket seals may leak around the intake ports, causing the lean condition.

    The TSB states that the intake gasket seals may be leaking around the intake ports, causing the lean condition.— [1]

  • Why it happensLeaks typically occur when the engine is cold and may subside as it warms.

    Leaks typically occur when the engine is cold, and may subside as the engine warms.— [1]

  • How to confirmThe seals may leak around the bottom side of the port, which makes the vacuum leak hard to detect.

    The intake gasket seals may leak around the bottom side of the port, making it difficult to detect the vacuum leak.— [1]

  • How to confirmLower-than-normal MAF readings may be seen if the intake seals are leaking.

    You may also notice lower-than-normal MAF readings if the intake seals are leaking.— [1]

  • RepairOnly the current teal green gaskets should be used; the old gaskets were orange.

    That part number will have a teal green intake gasket seal. The old versions of the intake gaskets were orange in color. Only the teal green colored gaskets should be used.— [1]

  • RepairThe intake bolts must be replaced and not reused.

    The intake bolts must be replaced and should not be reused.— [1]

  • How to confirmAn intake manifold with warpage in excess of 3mm (.118 in.) over a 200mm (7.87-in.) area must be replaced.

    An intake manifold with warpage in excess of 3mm (.118 in.) over a 200mm (7.87-in.) area must be replaced.— [1]

  • Applies toThe row is for 2002-2004 Silverado, Suburban, Tahoe, Sierra, Yukon/XL and Escalade EXT with rough idle, misfire and MIL with DTC P0300.

    2002-2004 Silverado, Suburban, Tahoe, Sierra, Yukon/XL, Escalade EXT – Rough Idle, Misfire, MIL DTC P0300— [2]

  • How to confirmMeasure the intake manifold for warpage across two runner ports only.

    Measure intake manifold for warpage across two runner ports only.— [2]

  • RepairReplace the upper manifold gasket with the teal-green gasket.

    Replace upper manifold gasket with teal-green gasket.— [2]

  • CautionDo not measure the intake manifold across all four intake runner ports.

    Don’t measure intake manifold across all four intake runner ports.— [2]

  • CautionDo not replace the upper intake manifold gasket with an orange gasket.

    Don’t replace upper intake manifold gasket with orange gasket.— [2]

  • RepairA new gasket made of FNK material (GM SPO p/n 89017589) has been released; the new gasket material is teal green, and the original gaskets are orange.

    A new gasket made of FNK material (GM SPO p/n 89017589) has been released. The new gasket material is teal green in color (fig. 7) ; the original gaskets are orange.— [3] Upper Manifold Gasket Leak

  • RepairUse only the 89017589 gasket (teal green) for repairs on the L59 engine.

    Use only the 89017589 gasket (teal green) for repairs on the L59 engine, and do not replace the upper manifold unless it measures outside of the service manual specifications or is damaged.— [3] Upper Manifold Gasket Leak

  • Applies toThis article applies specifically to the 5.3L L59 (E85 capable), as well as the other Gen 3 and Gen 4 engines.

    This information applies specifically to the 5.3L L59 (E85 capable), as well as the other Gen 3 and Gen 4 engines.— [3] Upper Manifold Gasket Leak

Put together by FaultCrate from public records and technical documents. The cause and the repair are for the workshop to decide with the vehicle in front of it. Counts are records, not failure rates.

Records under this issue 11

Owner complaint 1Manufacturer communication 10

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