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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1443 (Engine Mechanical - 4.2L (Ll8)) >> Repair Instructions >> On-Vehicle Repair Instructions >> Intake Manifold Replacement >> Installation Procedure

Installation Procedure

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  1. Install a new intake manifold gasket to the intake manifold.
    2. Fig 1: View Of Intake Manifold & Bolts
    GM637631Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the intake manifold onto the engine and secure the manifold with the bolts.

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

  3. Install the generator. Refer to Generator Replacement (4.2L Engine) in Engine Electrical.
    4. Fig 2: Disconnecting/Connecting Vacuum Brake Booster Hose
    GM748028Courtesy of GENERAL MOTORS CORP.
  4. Install the vacuum brake booster hose to the intake manifold.
    5. Fig 3: View Of Crankcase Ventilation Hose Location
    GM637635Courtesy of GENERAL MOTORS CORP.
  5. Lubricate the inner diameter of the crankcase ventilation hose with GM P/N 12345884 (Canadian P/N 5728223) or equivalent.
  6. Install the crankcase ventilation hose.
    7. Fig 4: View Of MAP Sensor Electrical Connector
    GM732831Courtesy of GENERAL MOTORS CORP.
  7. Connect the MAP sensor electrical connector.
  8. Properly position the engine electrical harness bracket to the intake manifold.
    9. Fig 5: View Of Engine Wire Harness Bracket & Bolts
    GM1348786Courtesy of GENERAL MOTORS CORP.
  9. Install the engine electrical harness bracket bolt.

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

    10. Fig 6: Fuel Feed And Fuel Return Pipes (Left Side Of Engine)
    GM730718Courtesy of GENERAL MOTORS CORP.
  10. Connect the integral clip (3) to the wire harness bracket.
  11. Connect the fuel feed (1) and fuel return (2) pipes to the fuel rail. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
    12. Fig 7: View Of Engine Coolant Temperature Electrical Connector
    GM1288027Courtesy of GENERAL MOTORS CORP.
  12. Connect the ECT sensor electrical connector (1).
    13. Fig 8: View Of PCM Assembly
    GM1284769Courtesy of GENERAL MOTORS CORP.
  13. Install the PCM mounting studs (5) to the intake manifold.

    Tighten:  Tighten the studs to 6 N.m (53 lb in).

  14. Install the PCM (1) onto the studs (5).
  15. Install the PCM retaining bolts (3).

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

  16. Install the PCM retaining nuts (6).

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

  17. Install the throttle body. Refer to Throttle Body Assembly Replacement in Engine Controls - 4.2L.
  18. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  19. Inspect for leaks using the following procedure:
    1. Turn ON the ignition, with the engine OFF for 2 seconds.
    2. Turn OFF the ignition, for 10 seconds.
    3. Turn ON the ignition, with the engine OFF.
    4. Inspect for fuel leaks.
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