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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1444 (Engine Mechanical - 5.3L (Lm4)) >> Repair Instructions >> On-Vehicle Repair Instructions >> Intake Manifold Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Envoy XUV, 2004 GMC Envoy XL, 2004 Chevrolet TrailBlazer, and 2004 Buick Rainier. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Intake Manifold Gasket
    GM492770Courtesy of GENERAL MOTORS CORP.
  1. Install NEW intake manifold gaskets (1) to the intake manifold.
    2. Fig 2: View of Intake Manifold
    GM825839Courtesy of GENERAL MOTORS CORP.
  2. Install the intake manifold.
  3. Apply a 5 mm (0.20 in) bead of threadlock GM P/N 12345382, (Canadian P/N 10953489) or equivalent to the threads of the intake manifold bolts.
    4. Fig 3: Identifying Intake Manifold Bolt Tightening Sequence
    GM63222Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Install the intake manifold bolts.

    Tighten: 

    1. Tighten the bolts a first pass in sequence to 5 N.m (44 lb in).
    2. Tighten the bolts a final pass in sequence to 10 N.m (89 lb in).

    5. Fig 4: View Of Upper Engine Wire Harness Retainer Nut
    GM899740Courtesy of GENERAL MOTORS CORP.
  5. Route the electrical harness into position over the engine.
  6. Install the engine harness bracket nut (1).

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

    7. Fig 5: View Of Vacuum Brake Booster Hose
    GM898352Courtesy of GENERAL MOTORS CORP.
  7. Install the vacuum brake booster hose to the rear of the intake manifold.
    8. Fig 6: View Of EVAP Purge Solenoid Vent Tube
    GM898353Courtesy of GENERAL MOTORS CORP.
  8. Install the EVAP purge solenoid vent tube.
    9. Fig 7: View Of Heater Water Shutoff Valve Actuator Inlet Hose
    GM898349Courtesy of GENERAL MOTORS CORP.
  9. Install the heater water shutoff valve actuator inlet hose to the intake manifold.
    10. Fig 8: View Of PCV Foul Air Hose
    GM1386395Courtesy of GENERAL MOTORS CORP.
  10. Install the PCV hose.
  11. Install the knock sensor harness electrical connector to the intake manifold.
    12. Fig 9: Top Of Engine Wiring Harness View
    GM898326Courtesy of GENERAL MOTORS CORP.
  12. Connect the following electrical connectors:
    • EVAP purge solenoid (1)
    • Knock sensor (2)
    • MAP sensor (3)
    • Main coil (5)
    • Fuel injectors (4)
    13. Fig 10: Disconnecting/Connecting Fuel Injector Connector
    GM1209783Courtesy of GENERAL MOTORS CORP.
  13. Perform the following steps in order to connect the fuel injector electrical connectors.
    1. Install the connectors to their corresponding injectors to ensure correct reassembly.
    2. Connect the fuel injector electrical connector.
    3. Push the CPA retainer (2) on the connector in one click.
    4. Repeat the steps for each injector electrical connector.
  14. Install the harness clips to the fuel rail.
    15. Fig 11: Disconnecting/Connecting Generator Electrical Connector
    GM898329Courtesy of GENERAL MOTORS CORP.
  15. Connect the generator electrical connector.
    16. Fig 12: Locating Electrical Components At Top Of Engine
    GM898331Courtesy of GENERAL MOTORS CORP.
  16. Connect the following electrical connectors:
    • Main coil (1)
    • ETC (2)
    • Fuel injectors (3)
  17. Install the electrical harness clips to the fuel rail.
    18. Fig 13: View Of A/C Compressor Pressure Switch Electrical Connector & Retaining Clip
    GM898468Courtesy of GENERAL MOTORS CORP.
  18. Connect the A/C compressor pressure switch electrical connector (2).
  19. Install the harness clip to the cylinder head.
    20. Fig 14: View Of MAF/IAT Sensor Electrical Connector
    GM1204792Courtesy of GENERAL MOTORS CORP.
  20. Connect the MAF/IAT sensor electrical connector (1).
  21. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement in Engine Controls.
  22. Install the fuel fill cap.
  23. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  24. Use the following procedure in order to inspect for leaks:
    1. Turn the ignition ON, with the engine OFF, for 2 seconds.
    2. Turn the ignition OFF for 10 seconds.
    3. Turn the ignition ON, with the engine OFF.
    4. Inspect for fuel leaks.
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