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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 - Upper >> 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. If removed, install the throttle body. Refer to THROTTLE BODY in Engine Performance - Removal and Installation
    Fig 1: Installing Throttle Body
    G02081372Courtesy of GENERAL MOTORS CORP.
  2. Install the upper intake manifold gaskets.
  3. Install the upper intake manifold.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  4. Install the upper intake manifold bolts and the stud.
    1. Tighten 
    2. Tighten the bolts and the stud to 25 N.m (18 lb ft).
  5. Install the EGR valve. Refer to EGR VALVE in Engine Performance - Removal and Installation.
  6. Install the MAP sensor bracket and the sensor. Refer to MANIFOLD ABSOLUTE PRESSURE SENSOR in Engine Performance - Removal and Installation.
  7. Install the EVAP canister purge valve. Refer to EVAP CANISTER PURGE VALVE in Engine Performance - Removal and Installation.
  8. Install the ignition coil bracket with the coils. Refer to IGNITION COILS in Engine Performance - Removal and Installation.
  9. Install the thermostat bypass pipe coolant hoses (3,4) to the throttle body.
  10. Install the following wiring harnesses to the retainers:
    • Engine wiring harness
    • Left side spark plug wire harness
    • Camshaft position (CMP) sensor wiring harness
    Fig 2: Installing Upper Intake Manifold Gaskets
    G02081373Courtesy of GENERAL MOTORS CORP.
  11. Install the left side spark plug wires to the spark plugs. Refer to SPARK PLUGS in Engine Performance - Removal and Installation.
  12. Connect the electrical connectors to the following:
    • Evaporative emission (EVAP) canister purge valve
    • Throttle position (T/P) sensor
    • Idle air control (IAC) valve
    • Mass air flow (MAF) sensor
    • Exhaust gas recirculation (EGR) valve
    Fig 3: Installing Thermostat Bypass Pipe Coolant Hoses
    G02081374Courtesy of GENERAL MOTORS CORP.
  13. Install the vacuum hoses to the following:
    • Windshield washer system
    • Brake booster to the upper intake manifold
    • Manifold vacuum source
    • Evaporative emissions (EVAP) canister purge valve
    • Fuel pressure regulator
  14. Install the accelerator controls cable bracket with the accelerator control and the cruise control cables.
  15. Install the air cleaner intake duct.
  16. Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Battery.
  17. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
    Fig 4: Installing Air Cleaner Intake Duct
    G02081375Courtesy of GENERAL MOTORS CORP.
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