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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 >> Removal Procedure

Removal 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.
IMPORTANT: The intake manifold, throttle body, fuel rail, and injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.
  1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement in Engine Controls.
  2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure in Engine Controls.
    3. Fig 1: View Of A/C Compressor Pressure Switch Electrical Connector & Retaining Clip
    GM898468Courtesy of GENERAL MOTORS CORP.
  3. Disconnect the air conditioning (A/C) compressor pressure switch electrical connector (2).
  4. Remove the harness clip from the cylinder head.
    5. Fig 2: View Of MAF/IAT Sensor Electrical Connector
    GM1204792Courtesy of GENERAL MOTORS CORP.
  5. Disconnect the mass air flow (MAF)/intake air temperature (IAT) sensor electrical connector (1).
  6. Remove the harness clips from the fuel rail.
    7. Fig 3: Locating Electrical Components At Top Of Engine
    GM898331Courtesy of GENERAL MOTORS CORP.
  7. Disconnect the following electrical connectors:
    • Main coil (1)
    • Electronic throttle control (ETC) (2)
    • Fuel injectors (3)
    8. Fig 4: Disconnecting/Connecting Fuel Injector Connector
    GM1209783Courtesy of GENERAL MOTORS CORP.
  8. Perform the following steps in order to disconnect the fuel injector electrical connector.
    1. Mark the connectors to their corresponding injectors to ensure correct reassembly.
    2. Pull the connector position assurance (CPA) retainer (2) on the connector up 1 click.
    3. Push the tab (1) on the connector in.
    4. Disconnect the fuel injector electrical connector.
    5. Repeat the steps for each injector electrical connector.
    9. Fig 5: Disconnecting/Connecting Generator Electrical Connector
    GM898329Courtesy of GENERAL MOTORS CORP.
  9. Disconnect the generator electrical connector.
    10. Fig 6: Top Of Engine Wiring Harness View
    GM898326Courtesy of GENERAL MOTORS CORP.
  10. Disconnect the following electrical connectors:
    • Evaporative emission (EVAP) purge solenoid (1)
    • Knock sensor (2)
    • Manifold absolute pressure (MAP) sensor (3)
    • Main coil (5)
    • Fuel injectors (4)
  11. Remove the electrical harness clips from the fuel rail.
  12. Remove the knock sensor harness electrical connector from the intake manifold.
    13. Fig 7: View Of PCV Foul Air Hose
    GM1386395Courtesy of GENERAL MOTORS CORP.
  13. Remove the positive crankcase ventilation (PCV) hose.
    14. Fig 8: View Of Heater Water Shutoff Valve Actuator Inlet Hose
    GM898349Courtesy of GENERAL MOTORS CORP.
  14. Remove the heater water shutoff valve actuator inlet hose from the intake manifold.
    15. Fig 9: View Of EVAP Purge Solenoid Vent Tube
    GM898353Courtesy of GENERAL MOTORS CORP.
  15. Remove the evaporative emission (EVAP) purge solenoid vent tube by performing the following:
    1. Remove the EVAP tube end from the solenoid.
    2. Squeeze the EVAP pipe quick connect fitting retainer together.
    3. Remove the EVAP tube end from the vapor pipe.
    16. Fig 10: View Of Vacuum Brake Booster Hose
    GM898352Courtesy of GENERAL MOTORS CORP.
  16. Remove the vacuum brake booster hose from the rear of the intake manifold.
    17. Fig 11: View Of Upper Engine Wire Harness Retainer Nut
    GM899740Courtesy of GENERAL MOTORS CORP.
  17. Remove the upper engine wire harness retainer nut (1).
  18. Reposition the upper engine wire harness aside.
    19. Fig 12: View of Intake Manifold
    GM825839Courtesy of GENERAL MOTORS CORP.
  19. Remove the intake manifold bolts.
  20. Remove the intake manifold.
    21. Fig 13: View Of Intake Manifold Gasket
    GM492770Courtesy of GENERAL MOTORS CORP.
  21. Remove the intake manifold gaskets (1) from the intake manifold.
  22. Discard the old intake manifold gaskets.
  23. If necessary, clean and inspect the intake manifold. Refer to Intake Manifold Cleaning and Inspection  .
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