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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1243 (Engine Mechanical - 3.1L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Intake Manifold Replacement - Lower >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2003 Pontiac Grand Prix. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the thermostat.
    Fig 1: Installing Thermostat
    G02081390Courtesy of GENERAL MOTORS CORP.
  2. Install the water outlet.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  3. Install the water outlet bolts.

    Tighten 

    Tighten the bolts to 25 N.m (18 lb ft).

    Fig 2: Installing Water Outlet
    G02081391Courtesy of GENERAL MOTORS CORP.
  4. Install the ECT sensor.

    Tighten 

    Tighten the sensor to 25 N.m (18 lb ft).

    Fig 3: Installing ECT Sensor
    G02081392Courtesy of GENERAL MOTORS CORP.
  5. Apply 8-12 mm (0.08-0.11 in) bead of RTV Sealer, GM P/N 12346286 (Canadian P/N 10953472) or equivalent, on each ridge where front and rear of the lower intake manifold contact the engine block (1).
  6. Install the lower intake manifold gaskets.
    NOTE: When replacing lower intake manifold gasket, a revised intake manifold gasket has been introduced by manufacturer. This new design gasket helps resolve issues related to intake manifold oil/coolant leaks. The gasket requires a revised torque specification and procedure in addition to the use of NEW revised intake manifold bolts. Please review TSB 03-06-01-010C ENGINE OIL OR COOLANT LEAK (INSTALL NEW INTAKE MANIFOLD GASKET) for complete information.
  7. Install the valve rocker arms and pushrods. Refer to VALVE ROCKER ARM AND PUSH ROD REPLACEMENT  .
    Fig 4: Installing Lower Intake Manifold Gaskets
    G02081393Courtesy of GENERAL MOTORS CORP.
  8. Install the lower intake manifold.
  9. Apply sealant, GM P/N 12345382 (Canadian P/N 10953489) to the threads of the bolts.
    Fig 5: Installing Lower Intake Manifold
    G02081394Courtesy of GENERAL MOTORS CORP.
    NOTE: An oil leak may result if the vertical bolts are not tightened before the diagonal bolts.
  10. Install the lower intake manifold bolts (1, 2). See Fig 6

    Tighten See TSB 03-06-01-010C for revised lower intake bolt torque.

    Fig 6: Installing Lower Intake Manifold Bolts
    G02081395Courtesy of GENERAL MOTORS CORP.
  11. Install the thermostat bypass hose to the thermostat bypass pipe and lower intake manifold pipe.
  12. Install the heater inlet pipe nut.

    Tighten 

    Tighten the nut to 25 N.m (18 lb ft).

  13. Install the radiator inlet hose to the engine. Refer to RADIATOR HOSE REPLACEMENT - INLET (3.1 L) in Engine Cooling.
    Fig 7: Installing Thermostat Bypass Hose To Thermostat Bypass Pipe And Lower Intake Manifold Pipe
    G02081396Courtesy of GENERAL MOTORS CORP.
  14. Install the heater inlet pipe and heater hose to the lower intake manifold.
  15. Install the power steering pump to the front engine cover. Refer to POWER STEERING PUMP REPLACEMENT (3.1L) in Power Steering System.
    Fig 8: Installing Heater Inlet Pipe And Heater Hose To Lower Intake Manifold
    G02081397Courtesy of GENERAL MOTORS CORP.
  16. Install the fuel injector rail.
    Fig 9: Installing Fuel Injector Rail
    G02081398Courtesy of GENERAL MOTORS CORP.
  17. Install the fuel return pipe to the fuel injector rail.
    Fig 10: Installing Fuel Return Pipe To Fuel Injector Rail
    G02081399Courtesy of GENERAL MOTORS CORP.
  18. Install the fuel feed pipe to the fuel injector rail.
    Fig 11: Installing Fuel Feed Pipe To Fuel Injector Rail
    G02081400Courtesy of GENERAL MOTORS CORP.
  19. Install the fuel pipe clip.
    Fig 12: Installing Fuel Pipe Clip
    G02081401Courtesy of GENERAL MOTORS CORP.
  20. Install the fuel pipe clip bolt.

    Tighten 

    Tighten the bolt to 8 N.m (71 lb in).

    Fig 13: Installing Fuel Pipe Clip Bolt
    G02081402Courtesy of GENERAL MOTORS CORP.
  21. Install and connect the fuel injector and the MAP sensor wiring harnesses.
    Fig 14: Connecting Fuel Injector And MAP Sensor Wiring Harnesses
    G02081403Courtesy of GENERAL MOTORS CORP.
  22. Connect the ECT sensor electrical connector.
  23. Install the right valve rocker arm cover. Refer to VALVE ROCKER ARM COVER REPLACEMENT - RIGHT  .
  24. Install the left valve rocker arm cover. Refer to VALVE ROCKER ARM COVER REPLACEMENT - LEFT  .
  25. Install the upper intake manifold. Refer to INTAKE MANIFOLD REPLACEMENT - UPPER  .
  26. Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Battery.
  27. Inspect for leaks.
    Fig 15: Connecting ECT Sensor Electrical Connector
    G02081404Courtesy of GENERAL MOTORS CORP.
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