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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1224 (Engine Mechanical - 3.8L (On-Vehicle)) >> Repair Instructions >> Intake Manifold Replacement - Upper >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2002 Pontiac Grand Prix. However, it is still accessible from the selected car via links, so may be relevant.
  1. If the upper intake manifold is being replaced install the following:
    • Vacuum source manifold
    • Positive crankcase ventilation (PCV) valve
    • Manifold absolute pressure (MAP) sensor
    • Throttle body
  2. Install the upper-to-lower intake manifold carrier gasket to the upper intake manifold.
    Fig 1: Upper Intake Manifold & Carrier Gasket
    G01703195Courtesy of GENERAL MOTORS CORP.
  3. Carefully place the upper intake manifold onto the lower intake manifold. Ensure that the alignment pins in the upper intake manifold align with the holes in the lower intake manifold.
  4. Install the upper intake manifold.
  5. Apply thread lock compound GM P/N 12345382 (Canadian P/N 1095348) or equivalent, to the bolt threads before assembly.
    Fig 2: Upper Intake Manifold
    G01703196Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to FASTENER NOTICE .
  6. Install the upper intake manifold bolts (1-10).

    Tighten 

    Tighten the upper intake manifold bolts in sequence to 10 N.m (89 lb in).

  7. Install the accelerator and the cruise control bracket to the throttle body.
  8. Install the EVAP purge solenoid vacuum line to the throttle body.
  9. Connect the electrical connectors to the following:
    • Mass air flow (MAF) sensor
    • Manifold absolute pressure (MAP) sensor
    • Idle air control (IAC) valve
    • The throttle position (TP) sensor
    • EVAP purge solenoid
      Fig 3: Installing Upper Intake Manifold Bolts
      G01703197Courtesy of GENERAL MOTORS CORP.
  10. Install the throttle body upper support bracket bolt.

    Tighten 

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

    Fig 4: Throttle Body Upper Support Bracket
    G01703198Courtesy of GENERAL MOTORS CORP.
  11. Install the EGR valve wiring harness heat shield, nut and the bolt to the upper intake manifold.

    Tighten 

    Tighten the nut and the bolt to 10 N.m (89 lb in).

  12. Install the brake booster hose to the vacuum source manifold.
  13. Install the fuel rail assembly. Refer to FUEL RAIL & INJECTORS .
  14. Install the right spark plug wires to the ignition control module.
  15. Install the air cleaner intake duct. Refer to AIR CLEANER INTAKE DUCT .
  16. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (L36)  or Fuel Injector Sight Shield Replacement (L67) .
  17. Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE .
  18. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM .
  19. Inspect for fluid or vacuum leaks.
    Fig 5: EGR Valve Wiring Harness Heat Shield
    G01703199Courtesy of GENERAL MOTORS CORP.
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