LEMON Manuals: Even more car manuals for everyone
Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical - 4.3L (On-Vehicle) >> Repair Instructions >> Intake Manifold Replacement - Lower >> Installation Procedure

Installation Procedure

NOTE: Apply the proper amount of the sealant when assembling this component. Excessive use of the sealant can prohibit the component from sealing properly. A component that is not sealed properly can leak leading to extensive engine damage.
  1. Apply a 4.0 mm (0.157 in) patch of adhesive GM P/N 12346141 or equivalent to the cylinder head side of the lower intake manifold gasket at each end.

    Important:  The lower intake manifold gasket must be installed while the adhesive is still wet to the touch.

  2. Install the lower intake manifold gasket onto the cylinder head.

    Use the gasket locator pins in order to properly seat the lower intake manifold gasket on the cylinder head.

    Fig 1: Applying Adhesive To Cylinder Head Side Of Lower Intake Manifold Gasket
    G01661048Courtesy of GENERAL MOTORS CORP.
    NOTE: Apply the proper amount of the sealant when assembling this component. Excessive use of the sealant can prohibit the component from sealing properly. A component that is not sealed properly can leak leading to extensive engine damage.

    Important:  The lower intake manifold must be installed and the fasteners tightened while the adhesive is still wet to the touch.

  3. Apply a 5 mm (0.197 in) bead of adhesive GM P/N 12346141 or equivalent to the front top of the engine block.
  4. Extend the adhesive bead 13 mm (0.50 in) onto each lower intake manifold gasket.
    Fig 2: Applying Adhesive To Front Top Of Engine Block & Lower Intake Manifold Gasket
    G01661049Courtesy of GENERAL MOTORS CORP.
  5. Apply a 5 mm (0.197 in) bead of adhesive GM P/N 12346141 or equivalent to the rear top of the engine block.
  6. Extend the adhesive bead 13 mm (0.50 in) onto each lower intake manifold gasket.
    Fig 3: Applying Adhesive To Rear Top Of Engine Block & Lower Intake Manifold Gasket
    G01661050Courtesy of GENERAL MOTORS CORP.
  7. Install the lower intake manifold onto the engine block.
  8. If reusing the fasteners, apply threadlock GM P/N 12345382 or equivalent to the threads of the lower intake manifold bolts.
  9. Install the lower intake manifold bolts.
    Fig 4: Lower Intake Manifold & Bolts
    G01661051Courtesy of GENERAL MOTORS CORP.
    NOTE: Proper lower intake manifold fastener tightening sequence and torque is critical. Always follow the tightening sequence, and torque the intake manifold bolts using the 3 step method Failing to do so may distort the crankshaft bearing bore alignment and cause damage to the crankshaft bearings.
    NOTE: Refer to FASTENER NOTICE .
  10. Tighten the lower intake manifold bolts.

    Tighten 

    1. 10.1 Tighten the bolts on the first pass in sequence to 3 N.m (27 lb in).
    2. 10.2 Tighten the bolts on the second pass in sequence to 12 N.m (106 lb in).
    3. 10.3 Tighten the bolts on the final pass in sequence to 15 N.m (11 lb ft).
    Fig 5: Lower Intake Manifold Bolts Tightening Sequence
    G01661052Courtesy of GENERAL MOTORS CORP.
  11. Position the power steering pump mounting bracket.
  12. Loosely install the power steering pump mounting bracket bolts and nuts.
  13. Install the nut for the power steering pump rear bracket at the front of the engine.

    Tighten 

    Tighten the power steering pump mounting bracket bolts and the power steering pump rear bracket nuts to 41 N.m (30 lb ft).

  14. Install the AIR reactor pipe bracket nut to the power steering pump rear bracket front stud, if equipped.

    Tighten 

    Tighten the AIR reactor pipe bracket nut to 41 N.m (30 lb ft).

    Fig 6: Power Steering Pump Brackets, Power Steering Pump, A/C Compressor Bolts & Nuts
    G01661053Courtesy of GENERAL MOTORS CORP.
  15. Install the drive belt. Refer to Drive Belt Replacement .
  16. Install the fuel supply and return pipes to the rear of the intake manifold.

    Important:  In order to install the distributor for the correct engine timing, position the engine to number one cylinder top dead center.

  17. Remove the spark plug for number one cylinder.
  18. Rotate the crankshaft until number one cylinder is in the compression stroke.
  19. Align the 2 reference marks on the crankshaft balancer (1) and (4) with the 2 alignment marks (2) and (3) on the front cover.
    20. Fig 7: Aligning Crankshaft Balancer Reference Marks With Front Cover Alignment Marks
    G01661054Courtesy of GENERAL MOTORS CORP.
  20. Install the spark plug.
  21. Install the distributor. Refer to DISTRIBUTOR .
  22. Install the EVAP canister purge solenoid valve. Refer to EVAP CANISTER PURGE SOLENOID .
  23. Install the EGR valve inlet pipe to the intake manifold and the exhaust manifold.

    Tighten 

    1. 23.1 Tighten the EGR valve inlet pipe intake manifold nut to 25 N.m (18 lb ft).
    2. 23.2 Tighten the EGR valve inlet pipe exhaust manifold nut to 30 N.m (22 lb ft).
    3. 23.3 Tighten the EGR valve inlet pipe clamp bolt 25 N.m (18 lb ft).
  24. Install the spark plug wire harness retainer on the EGR valve inlet pipe.
    Fig 8: EGR Valve Inlet Pipe & Bolt
    G01661055Courtesy of GENERAL MOTORS CORP.
  25. Install the PCV hose assembly to the intake manifold and the valve rocker arm cover.
    Fig 9: PCV Hose Assembly
    G01661056Courtesy of GENERAL MOTORS CORP.
  26. Install the accelerator cable and cruise control cable bracket to the throttle body.

    Tighten 

    Tighten the accelerator cable and cruise control bracket nuts to 9 N.m (80 lb in).

    Fig 10: Accelerator Cable & Cruise Control Cable Bracket & Nuts
    G01661057Courtesy of GENERAL MOTORS CORP.
  27. Install the accelerator cable bracket to the intake manifold and the throttle body.

    Tighten 

    Tighten the accelerator cable bracket studs and nuts to 12 N.m (106 lb in).

    Fig 11: Accelerator Cable Bracket, Nuts & Stud
    G01661058Courtesy of GENERAL MOTORS CORP.
  28. Position the engine wiring harness.
  29. Install the engine wiring harness clips in the brackets.
  30. Connect the following electrical connectors:
    • The idle air control (IAC) motor (3)
    • The throttle position (TP) sensor (2)
    • The A/C compressor cutoff switch, if equipped (5)
    • The A/C clutch switch, if equipped (1)
    • The engine coolant temperature (ECT) sensor (4)
    Fig 12: IAC Motor, TP Sensor, A/C Compressor Cutoff Switch, A/C Clutch Switch & ECT Sensor Connectors
    G01661059Courtesy of GENERAL MOTORS CORP.
  31. Connect the following electrical connectors:
    • The fuel meter body assembly (1)
    • The EVAP canister purge solenoid valve (2)
    • The manifold air pressure (MAP) sensor (3)
    Fig 13: Fuel Meter Body Assembly, EVAP Canister Purge Solenoid Valve & MAP Sensor Connectors
    G01661060Courtesy of GENERAL MOTORS CORP.
  32. Connect the following electrical connectors:
    • The exhaust gas recirculation (EGR) valve (3)
    • The ignition coil (2)
    • The ignition control module (ICM) (1)
    • The generator (4)
    Fig 14: EGR Valve, Ignition Coil, ICM & Generator Electrical Connectors
    G01661061Courtesy of GENERAL MOTORS CORP.
  33. Connect the power brake booster vacuum hose.
  34. Connect the vacuum hose to the intake manifold, if equipped with A/C.
    Fig 15: Vacuum Hose
    G01661062Courtesy of GENERAL MOTORS CORP.
  35. Install the water pump inlet hose to the intake manifold.
    36. Fig 16: Water Pump Inlet Hose
    G01661063Courtesy of GENERAL MOTORS CORP.
  36. Install the heater hose to the intake manifold.
  37. Install the radiator inlet hose to the thermostat housing. Refer to RADIATOR HOSE REPLACEMENT - INLET (2.2L) or RADIATOR HOSE REPLACEMENT - INLET (4.3L) .
  38. Install the cruise control cable, if equipped to the bracket and the throttle shaft. Refer to CRUISE CONTROL CABLE REPLACEMENT (4.3L) or CRUISE CONTROL CABLE REPLACEMENT (2.2L) .
  39. Install the accelerator cable onto the throttle body.
    Fig 17: Accelerator Cable At Throttle Body
    G01661064Courtesy of GENERAL MOTORS CORP.
  40. Wrap the cable in between the finger of the hook tab and the pulley wall. Make sure that the cable is fully seated in the pulley groove. The cable must not lie outside of the hook tab.
    Fig 18: Proper Position Of Cable Between Hook Tab & Pulley Wall
    G01661065Courtesy of GENERAL MOTORS CORP.
  41. Install the accelerator cable to the accelerator cable control bracket.
    Fig 19: Accelerator Cable At Accelerator Cable Control Bracket
    G01661066Courtesy of GENERAL MOTORS CORP.
    NOTE:
    • Handle the MAF sensor carefully.
    • Do not drop the MAF sensor in order to prevent damage to the MAF sensor.
    • Do not damage the screen located on the air inlet end of the MAF.
    • Do not touch the sensing elements.
    • Do not allow solvents and lubricants to come in contact with the sensing elements.
    • Use a small amount of a soap based solution in order to aid in the installation
  42. Install air cleaner outlet duct to throttle body.
  43. Install air cleaner outlet duct to MAF sensor.

    Tighten 

    Tighten the hose clamp to 4 N.m (32 lb in).

    Fig 20: Air Cleaner Outlet Duct
    G01661067Courtesy of GENERAL MOTORS CORP.
  44. Connect the IAT sensor harness connector.
    Fig 21: IAT Sensor Harness Connector
    G01661068Courtesy of GENERAL MOTORS CORP.
  45. Install the air cleaner outlet duct retaining wingnut.

    Tighten 

    Tighten the wingnut to 2 N.m (18 lb in).

    Fig 22: Air Cleaner Outlet Duct Retaining Wingnut
    G01661069Courtesy of GENERAL MOTORS CORP.
  46. Connect the breather tube to the air cleaner outlet duct.
    47. Fig 23: Breather Tube
    G01661070Courtesy of GENERAL MOTORS CORP.
  47. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM .
  48. Connect the battery negative cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE .
scientia non olet · About LEMON Manuals