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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 >> Removal Procedure

Removal 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.
IMPORTANT: The intake manifold, throttle body, fuel rail, and injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.
  1. Loosen the clamps at the throttle body and air cleaner.
  2. Remove the air cleaner outlet duct.
    3. Fig 1: View Of Air Cleaner Outlet Duct
    GM700979Courtesy of GENERAL MOTORS CORP.
  3. Unsnap the intake manifold sight shield from the stud.
  4. Remove the sight shield from the bracket.
  5. Remove the sight shield bracket nuts (1) and bracket, if necessary.
    6. Fig 2: View Of Engine Sight Shield
    GM843779Courtesy of GENERAL MOTORS CORP.
  6. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure in Engine Controls - 8.1L.
  7. Disconnect the fuel feed and return pipes. Refer to Quick Connect Fitting(s) Service (Metal Collar) in Engine Controls - 8.1L.
  8. Disconnect the engine harness clips from the studs on the front of dash.
  9. Disconnect the engine harness clip from the wheelhouse splash shield.
  10. Disconnect the following electrical connectors:
    • Pressure cycling switch (1)
    • Surge tank switch (2)
    • Mass airflow (MAF) sensor (3)
    11. Fig 3: View Of MAF/IAT Sensor Electrical Connectors
    GM750582Courtesy of GENERAL MOTORS CORP.
  11. Reposition the engine harness branch to top of engine.
  12. Remove the connector position assurance (CPA) retainer at the ignition coil harness.
  13. Disconnect the following electrical connectors:
    • Manifold absolute pressure (MAP) sensor (1)
    • Ignition coil harness (2)
    • Engine coolant temperature (ECT) sensor (3)
    14. Fig 4: View Of Ignition Coil, ECT And MAP Sensor Electrical Connectors
    GM750529Courtesy of GENERAL MOTORS CORP.
  14. Remove the engine harness bolt and studs
  15. Remove the CPA retainer at the ignition coil harness.
  16. Disconnect the following electrical connectors:
    • Generator (2)
    • Injector harness (3)
    • Ignition coil harness (4)
    • Electronic throttle control (ETC) (5)
    • Purge valve solenoid (1)
    17. Fig 5: View Of Generator, Injector Harness, Ignition Coil Harness, ETC & Purge Valve Solenoid Electrical Connectors
    GM1235689Courtesy of GENERAL MOTORS CORP.
  17. Reposition the engine harness to the drivers side of the engine compartment.
  18. Remove the bypass valve vacuum hose (1) from the intake manifold.
    19. Fig 6: View Of Bypass Valve Vacuum Hose
    GM750614Courtesy of GENERAL MOTORS CORP.
  19. Disconnect the evaporative emission (EVAP) tube from the purge solenoid.
    20. Fig 7: View Of EVAP Purge Tube At Purge Solenoid
    GM843915Courtesy of GENERAL MOTORS CORP.
  20. Unclip the EVAP tube from the fuel rail.
    21. Fig 8: View Of EVAP Tube From At Fuel Rail
    GM843918Courtesy of GENERAL MOTORS CORP.
  21. Disconnect the EVAP tube from the vent pipe at the rear of the engine.
  22. Remove the EVAP tube.
  23. If replacing the intake manifold, remove the fuel rail studs.
  24. Remove the fuel rail.
    25. Fig 9: View Of Fuel Injection Rail
    GM1198692Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Do not attempt to loosen the manifold by prying under the gasket surface with any tool.
  25. Remove the intake manifold bolts.
    26. Fig 10: View Of Intake Manifold Bolts
    GM843795Courtesy of GENERAL MOTORS CORP.
  26. Remove the intake manifold.
    27. Fig 11: View Of Intake Manifold
    GM843798Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The intake manifold gaskets are not reusable.
  27. Remove and discard the intake manifold side gaskets.
    28. Fig 12: View Of Intake Manifold Gaskets
    GM843815Courtesy of GENERAL MOTORS CORP.
  28. Remove and discard the intake manifold end seals.
    29. Fig 13: View Of Intake Manifold End Seals
    GM843823Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The splash shield is secured using a snap-in fit. Do not distort the splash shield. The splash shield is reusable.
  29. Remove the splash shield.
    30. Fig 14: View Of Intake Manifold Splash Shield
    GM843827Courtesy of GENERAL MOTORS CORP.
  30. If replacing the intake manifold, refer to Intake Manifold Disassemble .
  31. Clean and inspect the intake manifold. Refer to Intake Manifold Cleaning and Inspection .
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