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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 124 (Engine Controls - Removal, Overhaul & Installation - Gasoline) >> Air Induction Systems >> Intake Manifold >> Removal & Installation (4.3L - Lower)

Removal & Installation (4.3L - Lower)

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2002 GMC Savana Special, 2002 GMC Savana Camper Special, 2002 GMC Savana, 2002 Chevrolet RV Cutaway, and 2002 Chevrolet Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: It is not necessary to remove the upper intake manifold in order to remove the intake manifold assembly.
  1. Disconnect the battery negative cable. Remove the engine cover. See ENGINE COVER . Drain the cooling system. Remove the retaining nut from the air cleaner outlet. Remove the air cleaner outlet duct from the throttle body assembly. Disconnect the harness connector of the Intake Air Temperature (IAT) sensor. Loosen the air cleaner outlet duct from the Mass Air Flow (MAF) sensor. Remove the air cleaner outlet duct. Remove the air cleaner assembly.
  2. Disconnect the accelerator control cable from the throttle shaft and the accelerator control cable bracket. Disconnect the cruise control cable (if equipped) from the throttle shaft and the accelerator control cable bracket. Disconnect the PCV valve hose assembly from the intake manifold and the valve rocker arm cover.
  3. Disconnect the Throttle Position (TP) sensor connector, the Idle Air Control (IAC) motor connector, the Engine Coolant Temperature (ECT) gauge sensor connector, the A/C high pressure switch connector, the fuel meter body assembly connector, the EVAP canister purge solenoid valve connector, the Manifold Absolute Pressure (MAP) sensor connector, the EGR valve connector, the Engine Coolant Temperature (ECT) sensor connector, the A/C compressor clutch connector (if equipped) and the ground wire from the stud at the water outlet.
  4. Remove the radiator inlet hose at the water outlet. Remove the heater hose from the intake manifold. Remove the water pump inlet hose from the intake manifold. Disconnect the A/C vacuum hose from the intake manifold. Disconnect the power brake booster vacuum hose from the intake manifold. Remove the power brake booster vacuum hose bracket and nut. Remove the accelerator control cable bracket from the throttle body and the intake manifold. Remove the EVAP canister purge solenoid valve.
  5. Remove the distributor. See DISTRIBUTOR  under IGNITION SYSTEMS. Disconnect the fuel supply and the return pipes at the rear of the intake manifold.
  6. Remove the ignition control module (ICM). See IGNITION CONTROL MODULE  under IGNITION SYSTEMS. Remove the spark plug wire harness retainer from the Exhaust Gas Recirculation (EGR) valve inlet pipe. Remove the clamp bolt for the EGR valve inlet pipe. Remove the EGR valve inlet pipe from the intake and the exhaust manifolds.
  7. In order to remove the front intake manifold bolt, perform the following: Remove the auxiliary evaporator tube from the A/C compressor (if equipped). Remove the drive belt. Loosen the nut for the power steering pump rear bracket. Remove the bolts and the nut for the power steering pump mounting bracket. Leave the A/C compressor (if equipped), and the power steering pump on the bracket. Slide the power steering pump bracket forward to access the bolt at the front of the intake manifold.
    8. WARNING: The intake manifold may be removed as an assembly. Do not remove the specific intake manifold components unless component service is required. Do not allow dirt or debris to enter the fuel system. Ensure that the ends of the fuel system are properly sealed. Do not disassemble the Central Sequential Fuel Injection (SFI) unit, unless service is required.
  8. Remove the engine coolant temperature (ECT) sensor wire connector (if equipped) from the engine wiring harness bracket. Remove the lower intake manifold bolts. Remove the intake manifold assembly. Remove and discard the lower intake manifold gaskets.
  9. Clean all sealing surfaces and the intake manifold. If the intake manifold requires replacement see appropriate article in ENGINES.
  10. Apply a 0.157" (4.0 mm) patch of Adhesive (GM 12346141) to the cylinder head side of the lower intake manifold gasket at each end. The lower intake manifold must be installed and the fasteners tightened while the adhesive is still wet to the touch. Install the lower intake manifold gasket onto the cylinder head. Use the gasket locator pins in order to properly seat the lower intake manifold gasket on the cylinder head. Apply a 0.197" (5 mm) bead of Adhesive (GM 12346141) to the front top of the engine block. Extend the adhesive bead 0.50" (13 mm) onto each lower intake manifold gasket. Apply a 0.197" (5 mm) bead of Adhesive (GM 12346141) to the rear top of the engine block. Extend the adhesive bead 0.50" (13 mm) onto each lower intake manifold gasket. Install the lower intake manifold onto the engine block. If reusing the fasteners, apply Threadlock (GM 12345382) to the threads of the lower intake manifold bolts. Install the lower intake manifold bolts.
  11. To complete installation, reverse removal procedure. See TORQUE SPECIFICATIONS . Install the engine cover.
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