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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 - Upper >> Installation Procedure

Installation Procedure

  1. Install the throttle body, if removed. Refer to THROTTLE BODY .
  2. Install the MAP sensor, if removed. Refer to MANIFOLD ABSOLUTE PRESSURE SENSOR .
  3. Install the PCV valve cover, if removed, using the following procedure:
    1. 3.1. Install a NEW seal (O-ring) on the PCV valve cover.
    2. 3.2. Lubricate the seal with clean engine oil.
    3. 3.3. Install the PCV valve cover in the upper intake manifold.
    4. 3.4. Turn and lock the PCV valve cover in position.
    Fig 1: PCV Valve Cover & Seal
    G01661010Courtesy of GENERAL MOTORS CORP.
  4. Install the power brake booster vacuum tube fitting, if removed, using the following procedure:
    1. 4.1 Install a NEW seal (O-ring) on the power brake booster vacuum tube fitting.
    2. 4.2 Lubricate the seal with clean engine oil.
    3. 4.3 Install the power brake booster vacuum tube fitting in the upper intake manifold.
    4. 4.4 Turn and lock the power brake booster vacuum tube fitting in position.
    Fig 2: Power Brake Booster Vacuum Tube Fitting & Seal
    G01661011Courtesy of GENERAL MOTORS CORP.
  5. Install a NEW seal on the fuel meter body assembly.
  6. Lubricate the seal with clean engine oil.
    Fig 3: Fuel Meter Body Assembly Seal
    G01661012Courtesy of GENERAL MOTORS CORP.
  7. Install a NEW upper intake manifold to lower intake manifold gasket in the groove of the upper intake manifold.
    Fig 4: Upper Intake Manifold & Gasket
    G01661013Courtesy of GENERAL MOTORS CORP.
  8. Install the upper intake manifold onto the lower intake manifold.
  9. If reusing the fasteners, apply threadlock GM P/N 12345382 or equivalent to the threads of the upper intake manifold attaching bolts.
    NOTE: Refer to FASTENER NOTICE .
  10. Install the upper intake manifold attaching studs.

    Tighten 

    1. 10.1 Tighten the upper intake manifold attaching studs on the first pass to 5 N.m (44 lb in).
    2. 10.2 Tighten the upper intake manifold attaching studs on the final pass to 9 N.m (80 lb in).
  11. Install the fuel lines to the fuel meter body assembly.
    Fig 5: Upper Intake Manifold & Studs
    G01661014Courtesy of GENERAL MOTORS CORP.
  12. Install the EVAP canister purge solenoid valve. Refer to EVAP CANISTER PURGE SOLENOID .
  13. Install the bracket for the engine wiring harness on the lower intake manifold stud.
  14. Install the engine wiring harness bracket nut.

    Tighten 

    Tighten the engine wiring harness bracket nut to 12 N.m (106 lb in).

    Fig 6: Engine Wiring Harness Bracket & Nut
    G01661015Courtesy of GENERAL MOTORS CORP.
  15. Install the accelerator and cruise control cable bracket to the throttle body.
  16. Install the accelerator and cruise control cable bracket nuts.

    Tighten 

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

    Fig 7: Accelerator & Cruise Control Cable Bracket & Nuts
    G01661016Courtesy of GENERAL MOTORS CORP.
  17. Install the accelerator control cable bracket to the throttle body and the intake manifold.

    Tighten 

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

    Fig 8: Accelerator Control Cable Bracket, Studs & Nuts
    G01661017Courtesy of GENERAL MOTORS CORP.
  18. Connect the PCV valve hose assembly to the intake manifold and the valve rocker arm cover.
    Fig 9: PCV Valve Hose Assembly
    G01661018Courtesy of GENERAL MOTORS CORP.
  19. Position the engine wiring harness.
  20. Install the wire harness clip to the accelerator cable bracket.
  21. Connect the following electrical connectors:
    • The fuel meter body assembly (1)
    • The manifold absolute pressure (MAP) sensor (3)
    • The EVAP canister purge solenoid valve (2)
    Fig 10: Fuel Meter Body Assembly, MAP Sensor & EVAP Canister Purge Solenoid Valve Electrical Connectors
    G01661019Courtesy of GENERAL MOTORS CORP.
  22. Connect the following electrical connectors:
    • The A/C compressor clutch (1)
    • The A/C compressor cutoff switch (5), if equipped
    • The throttle position (TP) sensor (2)
    • The idle air control (IAC) motor (3)
    Fig 11: A/C Compressor Clutch, Cutoff Switch, TP Sensor & IAC Motor Electrical Connectors
    G01661020Courtesy of GENERAL MOTORS CORP.
  23. Connect the vacuum hose from the vacuum tank to the intake manifold.
  24. Install the power brake booster vacuum hose to the intake manifold.
  25. Install the cruise control cable, if equipped to the throttle shaft and the bracket. Refer to CRUISE CONTROL CABLE REPLACEMENT (4.3L) or CRUISE CONTROL CABLE REPLACEMENT (2.2L) .
    Fig 12: Vacuum Hose
    G01661021Courtesy of GENERAL MOTORS CORP.
  26. Install the accelerator cable onto the throttle body.
    Fig 13: Accelerator Cable At Throttle Body
    G01661022Courtesy of GENERAL MOTORS CORP.
  27. 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 14: Proper Position Of Cable Between Hook Tab & Pulley Wall
    G01661023Courtesy of GENERAL MOTORS CORP.
  28. Install the accelerator cable to the accelerator cable control bracket.
    Fig 15: Accelerator Cable At Accelerator Cable Control Bracket
    G01661024Courtesy 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.
  29. Install air cleaner outlet duct to throttle body.
  30. Install air cleaner outlet duct to MAF sensor.

    Tighten 

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

    Fig 16: Air Cleaner Outlet Duct
    G01661025Courtesy of GENERAL MOTORS CORP.
  31. Connect the IAT sensor harness connector.
    Fig 17: IAT Sensor Harness Connector
    G01661026Courtesy of GENERAL MOTORS CORP.
  32. Install the air cleaner outlet duct retaining wingnut.

    Tighten 

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

    Fig 18: Air Cleaner Outlet Duct Retaining Wingnut
    G01661027Courtesy of GENERAL MOTORS CORP.
  33. Connect the breather tube to the air cleaner outlet duct.
    Fig 19: Breather Tube
    G01661028Courtesy of GENERAL MOTORS CORP.
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