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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1244 (Engine Mechanical - 3.8L) >> 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 the manifold was 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: Installing Gasket To Upper Intake Manifold
    G02083532Courtesy 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 10953489) or equivalent, to the bolt threads before assembly.
    Fig 2: Installing Upper Intake Manifold
    G02083533Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  6. Install the upper intake manifold bolts (1-10).

    Tighten 

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

  7. Install the accelerator and the cruise control cables with the bracket to the throttle body. Refer to ACCELERATOR CONTROLS CABLE BRACKET REPLACEMENT in Engine Performance - Removal and Installation.
  8. Install the EVAP purge solenoid vacuum line to the throttle body.
    Fig 3: Tightening Bolts In Sequence
    G02083534Courtesy of GENERAL MOTORS CORP.
  9. Connect the electrical connectors to the following:
    • Mass air flow (MAF) sensor
    • Manifold absolute pressure (MAP) sensor
    • Idle air control (IAC) valve
    • Throttle position (T/P) sensor
    • EVAP purge solenoid
  10. Install the throttle body upper support bracket bolt.

    Tighten 

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

    Fig 4: Installing Throttle Body Upper Support Bracket
    G02083535Courtesy of GENERAL MOTORS CORP.
  11. Install the EGR valve wiring harness heat shield, nut and bolt.

    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 ENGINE CONTROLS - REMOVAL & INSTALLATION - V6 & V8 or ENGINE CONTROLS - REMOVAL & INSTALLATION - V6 & V8 in Engine Performance - Removal and Installation.
  14. Install the right spark plug wires to the ignition control module. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION - V6 & V8 in Engine Performance - Removal and Installation.
  15. Install the air cleaner intake duct. Refer to AIR CLEANER INTAKE DUCT REPLACEMENT in Engine Performance - Removal and Installation.
  16. Install the fuel injector sight shield. Refer to FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L36)  or FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L67)  .
  17. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
  18. Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Battery.
  19. Inspect for fluid or vacuum leaks.
    Fig 5: Installing EGR Valve Wiring Harness Heat Shield
    G02083536Courtesy of GENERAL MOTORS CORP.
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