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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1018 (Engine Mechanical - 4.3L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Intake Manifold Replacement - Lower >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra and 2004 Chevrolet Silverado. However, it is still accessible from the selected car via links, so may be relevant.
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, (Canadian P/N 10953433), or equivalent to the cylinder head side of the intake manifold gasket at each end.
    IMPORTANT: The intake manifold gasket must be installed while the adhesive is still wet to the touch.
    2. Fig 1: Applying Patch Of Adhesive To Cylinder Head Side Of Intake Manifold Gasket
    GM38512Courtesy of GENERAL MOTORS CORP.
  2. Install the intake manifold gasket onto the cylinder head. Use the gasket locating pins in order to properly seat the gasket.
    3. IMPORTANT: The 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, (Canadian P/N 10953433), or equivalent to the front top of the engine block.
  4. Extend the adhesive bead 13 mm (0.50 in) up onto each intake manifold gasket.
    5. Fig 2: Applying Adhesive To Front Top Of Engine Block
    GM26744Courtesy of GENERAL MOTORS CORP.
  5. Apply a 5 mm (0.197 in) bead of adhesive GM P/N 12346141, (Canadian P/N 10953433), or equivalent to the rear top of the engine block.
  6. Extend the adhesive bead 13 mm (0.50 in) up onto each intake manifold gasket.
    7. Fig 3: Applying Adhesive To Rear Top Of Engine Block
    GM26743Courtesy of GENERAL MOTORS CORP.
  7. Install the intake manifold.
  8. If reusing the old fasteners, apply threadlock GM P/N 12345382, (Canadian P/N 10953489), or equivalent to the threads of the intake manifold - lower bolts.
  9. Install the intake manifold - lower bolts.
    10. Fig 4: Installing Intake Manifold & Bolts
    GM869728Courtesy 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 in Cautions and Notices.
  10. Tighten the intake manifold - lower bolts in the sequence shown.

    Tighten: 

    1. Tighten the bolts a first pass to 3 N.m (27 lb in).
    2. Tighten the bolts a second pass to 12 N.m (106 lb in).
    3. Tighten the bolts a final pass to 15 N.m (11 lb ft).

    11. Fig 5: Intake Manifold Lower Bolt Tightening Sequence
    GM188150Courtesy of GENERAL MOTORS CORP.
  11. Slide the P/S pump bracket rearward.
  12. Install the bolts and the nut for the P/S pump bracket.
  13. Install the P/S pump rear bracket front nut.
  14. Tighten the P/S pump rear bracket nut.

    Tighten:  Tighten the bolts and nuts to 41 N.m (30 lb ft).

    15. Fig 6: View Of Power Steering Pump Bracket
    GM340090Courtesy of GENERAL MOTORS CORP.
  15. Install the drive belt. Refer to Drive Belt Replacement .
  16. Install the water pump inlet hose.
    17. Fig 7: View Of Water Pump Inlet Hose & Clamps
    GM182853Courtesy of GENERAL MOTORS CORP.
  17. Position the water pump inlet hose clamps.
  18. Install the radiator inlet hose to the thermostat housing.
    19. Fig 8: Installing Radiator Inlet Hose To Thermostat Housing
    GM367002Courtesy of GENERAL MOTORS CORP.
  19. Position the radiator inlet hose clamps.
  20. Connect the power brake booster vacuum hose to the vacuum fitting.
    21. Fig 9: Connecting Power Brake Booster Vacuum Hose
    GM869713Courtesy of GENERAL MOTORS CORP.
  21. Install the PCV valve hose to the valve cover and rocker cover.
    22. Fig 10: Installing PCV Valve Hose
    GM869710Courtesy of GENERAL MOTORS CORP.
  22. Position the engine wiring harness and bracket.
  23. Install the engine wiring harness bracket stud.

    Tighten:  Tighten the stud to 25 N.m (18 lb ft).

  24. Install the engine wiring harness rear bracket nut at the EVAP canister purge solenoid valve.

    Tighten:  Tighten the nut to 9 N.m (80 lb in).

    25. Fig 11: Installing Engine Wiring Harness Bracket Stud & Rear Bracket Nut
    GM782176Courtesy of GENERAL MOTORS CORP.
  25. Install the engine wiring harness ground nut and ground wire (4) to the rear of the right cylinder head.

    Tighten:  Tighten the nut to 16 N.m (12 lb ft).

    26. Fig 12: Ignition Coil, Ignition Coil Driver, Ground Nut/Cable & Generator Electrical Connectors
    GM782177Courtesy of GENERAL MOTORS CORP.
  26. Install the engine wiring harness bracket.
  27. Install the engine wiring harness bracket nuts.

    Tighten:  Tighten the nuts to 12 N.m (106 lb in).

    28. Fig 13: Installing Engine Wiring Harness Bracket Nuts
    GM310241Courtesy of GENERAL MOTORS CORP.
  28. Connect the EVAP canister harness to the purge solenoid valve.
    29. Fig 14: Connecting EVAP Canister Harness
    GM869711Courtesy of GENERAL MOTORS CORP.
  29. Connect the following electrical connectors:
    • The EVAP canister purge solenoid valve (1)
    • The MAP sensor (2)
    30. Fig 15: EVAP Canister Purge Solenoid Valve & MAP Sensor Electrical Connectors
    GM782178Courtesy of GENERAL MOTORS CORP.
  30. Connect the following electrical connectors:
    • The TP sensor (1)
    • The IAC motor (2)
    • The control port injector module (3)
  31. Install the engine wiring harness clip bolt (4).

    Tighten:  Tighten the bolt to 9 N.m (80 lb in).

    32. Fig 16: View Of TP Sensor, IAC Motor, ECT Sensor, Control Port Injector Module & Engine Harness Clip Bolt
    GM782174Courtesy of GENERAL MOTORS CORP.
  32. Position the bracket and cables.
  33. Install the accelerator control cable bracket with the cables attached, to the throttle body.
  34. Install the accelerator control cable bracket nuts.

    Tighten:  Tighten the nuts to 9 N.m (80 lb in).

    35. Fig 17: View Of Accelerator Control Cable Bracket
    GM398030Courtesy of GENERAL MOTORS CORP.
  35. Connect the following electrical connectors:
    • The A/C compressor clutch (1), if equipped
    • The A/C pressure switch (4), if equipped
  36. Install the engine wiring harness clip (3) to the accelerator control cable bracket.
    37. Fig 18: A/C Compressor Clutch, Pressure Switch & Engine Wiring Harness Clip
    GM782175Courtesy of GENERAL MOTORS CORP.
  37. Install the accelerator cable to the accelerator control cable bracket.
    38. Fig 19: View Of Accelerator Cable To Accelerator Control Cable Bracket
    GM781990Courtesy of GENERAL MOTORS CORP.
  38. Install the accelerator cable to the throttle body lever.
    39. Fig 20: Installing Accelerator Cable To Throttle Body Lever
    GM781992Courtesy of GENERAL MOTORS CORP.
  39. Install the cruise control cable to the accelerator control cable bracket, if equipped.
  40. Connect the cruise control cable to the throttle lever, if equipped.
    41. Fig 21: Connecting Cruise Control Cable
    GM781993Courtesy of GENERAL MOTORS CORP.
  41. Position the heater inlet and outlet hoses.
  42. Open the heater inlet hose clamp and install the hose to the water pump.
    43. Fig 22: Installing Heater Inlet Hose To Water Pump
    GM869714Courtesy of GENERAL MOTORS CORP.
  43. Open the heater outlet hose clamp and install the hose to the intake manifold.
    44. Fig 23: Installing Heater Outlet Hose To Intake Manifold
    GM869717Courtesy of GENERAL MOTORS CORP.
  44. Install the heater hose clamp (1).
    45. Fig 24: Installing Heater Hose Clamp
    GM869718Courtesy of GENERAL MOTORS CORP.
  45. Install the fuel pipes/hoses. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls - 4.3L.
  46. Install the distributor. Refer to Distributor Replacement in Engine Controls - 4.3L.
  47. Fill the cooling system. Refer to Draining and Filling Cooling System (without HP2) in Engine Cooling.
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