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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1021 (Engine Mechanical - 8.1L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Intake Manifold Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. If replacing the intake manifold, refer to Intake Manifold Assemble .
  2. Install the splash shield.
    3. Fig 1: View Of Intake Manifold Splash Shield
    GM843827Courtesy of GENERAL MOTORS CORP.
  3. Ensure the splash shield (2) snap fits between the cylinder heads (1).
    4. Fig 2: View Of Splash Shield & Cylinder Heads
    GM843829Courtesy of GENERAL MOTORS CORP.
  4. Install the NEW intake manifold end seals.
    5. Fig 3: View Of Intake Manifold End Seals
    GM843823Courtesy of GENERAL MOTORS CORP.
  5. Install the NEW intake manifold side gaskets.
    6. Fig 4: View Of Intake Manifold Gaskets
    GM843815Courtesy of GENERAL MOTORS CORP.
  6. Ensure the intake manifold gasket tabs align with the hole in the head gasket.
    7. Fig 5: View Of Intake Manifold Gasket Tabs & Head Gasket Hole
    GM843835Courtesy of GENERAL MOTORS CORP.
  7. Ensure the intake manifold gasket tabs align with the slot in the intake manifold end seals.
  8. Install the intake manifold.
    9. Fig 6: View Of Intake Manifold
    GM843798Courtesy of GENERAL MOTORS CORP.
  9. Apply threadlock, GM P/N 12345382 (Canadian P/N 10953489), or equivalent to a minimum of eight threads of the intake manifold bolts.
  10. Install the intake manifold bolts.
    11. Fig 7: View Of Intake Manifold Bolts
    GM843795Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  11. Tighten the intake manifold bolts in the sequence shown, using four passes.

    Tighten: 

    1. Tighten the bolts a first pass to 5 N.m (44 lb in).
    2. Tighten the bolts a second pass to 8 N.m (71 lb in).
    3. Tighten the bolts a third pass to 12 N.m (106 lb in).
    4. Tighten the bolts a final pass to 15 N.m (11 lb ft).

    12. Fig 8: Intake Manifold Bolts Tightening Sequence
    GM843844Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Lubricate the fuel injector O-ring seals with clean engine oil and install onto the spray tip of each injector.
  12. If replacing the intake manifold, install the fuel rail.
    13. Fig 9: View Of Fuel Injection Rail
    GM1198692Courtesy of GENERAL MOTORS CORP.
  13. Install the fuel rail studs.

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

  14. Install the EVAP tube.
  15. Connect the EVAP tube to the vent pipe at the rear of the engine.
  16. Clip the EVAP tube to the fuel rail.
    17. Fig 10: View Of EVAP Tube From At Fuel Rail
    GM843918Courtesy of GENERAL MOTORS CORP.
  17. Connect the EVAP tube to the purge solenoid.
    18. Fig 11: View Of EVAP Purge Tube At Purge Solenoid
    GM843915Courtesy of GENERAL MOTORS CORP.
  18. Install the bypass valve vacuum hose (1) to the intake manifold.
    19. Fig 12: View Of Bypass Valve Vacuum Hose
    GM750614Courtesy of GENERAL MOTORS CORP.
  19. Position the engine harness over the engine compartment.
  20. Connect the following electrical connectors:
    • Generator (2)
    • Injector harness (3)
    • Ignition coil harness (4)
    • ETC (5)
    • Purge valve solenoid (1)
    21. Fig 13: View Of Generator, Injector Harness, Ignition Coil Harness, ETC & Purge Valve Solenoid Electrical Connectors
    GM1235689Courtesy of GENERAL MOTORS CORP.
  21. Install the CPA retainer at the ignition coil harness.
  22. Install the engine harness bolt and studs

    Tighten: 

    • Tighten the bolt to 16 N.m (12 lb ft).
    • Tighten the studs to 10 N.m (89 lb in).

  23. Connect the following electrical connectors:
    • MAP sensor (1)
    • Ignition coil harness (2)
    • ECT sensor (3)
    24. Fig 14: View Of Ignition Coil, ECT And MAP Sensor Electrical Connectors
    GM750529Courtesy of GENERAL MOTORS CORP.
  24. Install the CPA retainer at the ignition coil harness.
  25. Position engine harness branch over the top of engine.
  26. Connect the following electrical connectors:
    • Pressure cycling switch (1)
    • Surge tank switch (2)
    • MAF sensor (3)
    27. Fig 15: View Of MAF/IAT Sensor Electrical Connectors
    GM750582Courtesy of GENERAL MOTORS CORP.
  27. Connect the engine harness clip to the wheelhouse splash shield.
  28. Connect the engine harness clips to the studs on the front of dash.
  29. Connect the fuel feed and return pipes.
  30. Install the sight shield bracket and nuts (1).

    Tighten:  Tighten the nuts to 5 N.m (44 lb in).

    31. Fig 16: View Of Engine Sight Shield
    GM843779Courtesy of GENERAL MOTORS CORP.
  31. Install the sight shield to the bracket.
  32. Snap the intake manifold sight shield to the stud.
  33. Install the air cleaner outlet duct.
    34. Fig 17: View Of Air Cleaner Outlet Duct
    GM700979Courtesy of GENERAL MOTORS CORP.
  34. Tighten the clamps at the throttle body and air cleaner.

    Tighten:  Tighten the clamps to 4 N.m (35 lb in).

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