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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 - Upper >> 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.
  1. If required, install the purge solenoid valve.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the EVAP canister purge solenoid valve studs. If reusing the old studs, apply threadlock GM P/N 12345382, (Canadian P/N 10953489), or equivalent to the threads.

    Tighten:  Tighten the studs to 10 N.m (89 lb in).

    3. Fig 1: Installing EVAP Canister Purge Solenoid Valve
    GM334511Courtesy of GENERAL MOTORS CORP.
  3. If required, install a NEW MAP sensor seal. Apply a small drop of clean engine oil to the seal.
  4. Install the MAP sensor.
    5. Fig 2: Installing MAP Sensor
    GM480562Courtesy of GENERAL MOTORS CORP.
  5. If required, install a NEW throttle body gasket.
  6. Install the throttle body.
    7. Fig 3: View Of Throttle Body & Gasket
    GM12853Courtesy of GENERAL MOTORS CORP.
  7. Install the rear throttle body stud. If reusing the old stud, apply threadlock GM P/N 12345382, (Canadian P/N 10953489), or equivalent to the threads.

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

  8. If required, install a NEW O-ring seal to the PCV cover. Apply clean engine oil to the seal.
  9. Install the PCV valve cover.
    10. Fig 4: Installing PCV Valve Cover
    GM869707Courtesy of GENERAL MOTORS CORP.
  10. If required, install a NEW O-ring seal. Apply clean engine oil to the seal.
  11. Install the power brake booster vacuum fitting.
    12. Fig 5: Installing Power Brake Booster Vacuum Fitting
    GM516797Courtesy of GENERAL MOTORS CORP.
  12. Install a NEW O-ring seal to the fuel meter body.
    13. Fig 6: Installing Fuel Meter Body O-Ring Seal
    GM516773Courtesy of GENERAL MOTORS CORP.
  13. Install a NEW upper intake manifold gasket.
    14. Fig 7: Installing Upper Intake Manifold Gasket
    GM516790Courtesy of GENERAL MOTORS CORP.
  14. Install the intake manifold - upper.
    15. Fig 8: Installing Upper Intake Manifold
    GM516794Courtesy of GENERAL MOTORS CORP.
  15. If reusing the old throttle body/intake manifold studs, apply threadlock GM P/N 12345382, (Canadian P/N 10953489), or equivalent to the threads.
  16. Install the front two throttle body studs.
  17. Install the intake manifold - upper studs.

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

  18. Install the accelerator cable bracket.
  19. Install the accelerator cable bracket nuts.

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

    20. Fig 9: Installing Accelerator Cable Bracket & Nuts
    GM782205Courtesy of GENERAL MOTORS CORP.
  20. Connect the power brake booster vacuum hose to the vacuum fitting.
    21. Fig 10: 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 11: 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 12: 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 13: 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 14: Installing Engine Wiring Harness Bracket Nuts
    GM310241Courtesy of GENERAL MOTORS CORP.
  28. Connect the EVAP canister harness to the purge solenoid valve.
    29. Fig 15: 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 16: 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. Fig 17: View Of TP Sensor, IAC Motor, ECT Sensor, Control Port Injector Module & Engine Harness Clip Bolt
    GM782174Courtesy of GENERAL MOTORS CORP.
  31. Install the engine wiring harness clip bolt (4).

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

  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 18: 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 19: 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 20: 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 21: 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 22: Installing Cruise Control Cable
    GM781993Courtesy of GENERAL MOTORS CORP.
  41. Install the fuel pipes/hoses. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls-4.3L.
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