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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1496 (Engine Mechanical - 5.3L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Intake Manifold Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2003 GMC Envoy XL and 2003 Chevrolet TrailBlazer. 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 .
  2. Relieve the fuel system pressure. Refer to FUEL SYSTEM PRESSURE RELEASE .
  3. Disconnect the air conditioning (A/C) compressor pressure switch electrical connector (2).
  4. Remove the harness clip from the cylinder head.
    Fig 1: Disconnecting Air Conditioning (A/C) Compressor Pressure Switch Electrical Connector
    G02129080Courtesy of GENERAL MOTORS CORP.
  5. Disconnect the MAF/IAT sensor electrical connector (1).
    Fig 2: Disconnecting MAF/IAT Sensor Electrical Connector
    G02129081Courtesy of GENERAL MOTORS CORP.
  6. Remove the harness clips from the fuel rail.
  7. Disconnect the following electrical connectors:
    • Main coil (1)
    • Electronic throttle control (ETC) (2)
    • Fuel injectors (3)
      Fig 3: Disconnecting Following Electrical Connectors Components
      G02129082Courtesy of GENERAL MOTORS CORP.
  8. Perform the following steps in order to disconnect the fuel injector electrical connector.
    1. 8.1. Mark the connectors to their corresponding injectors to ensure correct reassembly.
    2. 8.2. Pull the connector position assurance (CPA) retainer (2) on the connector up 1 click.
    3. 8.3. Push the tab (1) on the connector in.
    4. 8.4. Disconnect the fuel injector electrical connector.
    5. 8.5. Repeat the steps for each injector electrical connector.
      Fig 4: Pushing Tab On Connector
      G02129083Courtesy of GENERAL MOTORS CORP.
  9. Disconnect the generator electrical connector.
    Fig 5: Disconnecting Generator Electrical Connector
    G02129084Courtesy 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 (4)
    • Fuel injectors (5)
    Fig 6: Locating Electrical Connectors At Intake Manifold
    G02129085Courtesy of GENERAL MOTORS CORP.
  11. Remove the electrical harness clips from the fuel rail.
  12. Remove the knock sensor harness electrical connector from the intake manifold.
  13. Remove the positive crankcase ventilation (PCV) hose (with valve).
    Fig 7: Removing Positive Crankcase Ventilation (PCV) Hose (With Valve)
    G02129086Courtesy of GENERAL MOTORS CORP.
  14. Remove the heater water shutoff valve actuator inlet hose from the intake manifold.
    Fig 8: Removing Heater Water Shutoff Valve Actuator Inlet Hose From Intake Manifold
    G02129087Courtesy of GENERAL MOTORS CORP.
  15. Remove the evaporative emission (EVAP) purge solenoid vent tube by performing the following:
    1. 15.1. Remove the EVAP tube end from the solenoid.
    2. 15.2. Squeeze the EVAP pipe quick connect fitting retainer together
    3. 15.3. Remove the EVAP tube end from the vapor pipe.
      Fig 9: Removing EVAP Tube End From Vapor Pipe
      G02129088Courtesy of GENERAL MOTORS CORP.
  16. Remove the vacuum brake booster hose from the rear of the intake manifold.
    Fig 10: Removing Vacuum Brake Booster Hose From Rear Of Intake Manifold
    G02129089Courtesy of GENERAL MOTORS CORP.
  17. Remove the upper engine wire harness retainer nut (1).
  18. Reposition the upper engine wire harness aside.
    Fig 11: Removing Upper Engine Wire Harness Retainer Nut
    G02129090Courtesy of GENERAL MOTORS CORP.
  19. Remove the intake manifold bolts.
  20. Remove the intake manifold.
    Fig 12: Removing Intake Manifold
    G02129091Courtesy of GENERAL MOTORS CORP.
  21. Remove the intake manifold gaskets (1) from the intake manifold.
    22. Fig 13: Removing Intake Manifold Gaskets From Intake Manifold
    G02129092Courtesy of GENERAL MOTORS CORP.
  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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