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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1537 (Engine Mechanical (Repair Instructions 1 Of 3) - 5.7L) >> Repair Instructions (On-Vehicle & Off-Vehicle - Part 1 >> On-Vehicle Repair Instructions >> Intake Manifold Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2004 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
IMPORTANT: The intake manifold, throttle body, fuel injection rail, and injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.
    Fig 1: Right Fuel Injection Rail Cover
    GM651872Courtesy of GENERAL MOTORS CORP.
  1. Drain the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling.
  2. If replacing the intake manifold, perform the following:
  3. Remove the right fuel rail cover.
    4. Fig 2: Left Fuel Rail Cover
    GM651873Courtesy of GENERAL MOTORS CORP.
  4. Remove the left fuel rail cover.
    5. Fig 3: EVAP Canister Purge Tube
    GM651868Courtesy of GENERAL MOTORS CORP.
  5. Remove the fuel feed hose. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls - 5.7 L.
  6. Disconnect the evaporative emission (EVAP) canister purge tube from the intake manifold.
  7. Disconnect the EVAP canister purge tube from the EVAP canister purge solenoid valve.
  8. Remove the EVAP canister purge tube.
    9. Fig 4: Fuel Feed Pipe
    GM651865Courtesy of GENERAL MOTORS CORP.
  9. Disconnect the EVAP canister purge tube from the EVAP canister purge solenoid valve.
  10. Disconnect the EVAP canister purge tube from the fuel feed pipe.
  11. Remove the EVAP canister purge tube.
    12. Fig 5: TP Sensor Electrical Connector
    GM51808Courtesy of GENERAL MOTORS CORP.
  12. Disconnect the throttle position (TP) sensor electrical connector.
  13. Remove the coolant air bleed hose. Refer to Coolant Air Bleed Hose Replacement in Engine Cooling.
    14. Fig 6: Throttle Body Heater Outlet Hose & Clamp
    GM672639Courtesy of GENERAL MOTORS CORP.
  14. Reposition the throttle body heater outlet hose clamp at the throttle body.
  15. Remove the throttle body heater outlet hose from the throttle body.
  16. Remove the throttle body heater outlet hose.
    17. Fig 7: Electrical Connectors
    GM651871Courtesy of GENERAL MOTORS CORP.
  17. Disconnect all the fuel injector electrical connectors (1).
  18. Disconnect the EVAP canister purge solenoid valve electrical connector (2).
  19. Disconnect the electronic throttle control (ETC) electrical connector (3).
    20. Fig 8: EVAP Canister Purge Solenoid Valve & Bracket
    GM419407Courtesy of GENERAL MOTORS CORP.
  20. Remove the EVAP canister purge solenoid valve from the bracket.
  21. Disconnect the harness clips at the fuel rails.
  22. Reposition the intake manifold branches of the wiring harness.
    23. Fig 9: Identifying Vacuum Booster Hose
    GM63936Courtesy of GENERAL MOTORS CORP.
  23. Disconnect the power brake booster vacuum hose at the booster.
    24. Fig 10: Knock Sensor Wire Harness Clip & Fuel Rail Stop Bracket
    GM639835Courtesy of GENERAL MOTORS CORP.
  24. Remove the knock sensor wire harness (1) clip from the fuel rail stop bracket (2).
    25. Fig 11: TP Sensor Harness Clip & PCV Tube
    GM379368Courtesy of GENERAL MOTORS CORP.
  25. Remove the TP sensor harness clip from the positive crankcase ventilation (PCV) tube.
  26. Remove the PCV tube from the right rocker arm cover and throttle body.
    27. Fig 12: Left Rocker Arm Cover & PCV Valve Pipe
    GM379366Courtesy of GENERAL MOTORS CORP.
  27. If equipped with the regular production option (RPO) LS1 engine, remove the PCV valve pipe from the left rocker arm cover.
    28. Fig 13: Right Rocker Arm Cover & PCV Valve Pipe
    GM379367Courtesy of GENERAL MOTORS CORP.
  28. If equipped with the RPO LS1 engine, remove the PCV valve pipe strap nut.
  29. Remove the PCV valve pipe from the right rocker arm cover and intake manifold.
    30. Fig 14: PCV Valve Hose
    GM668802Courtesy of GENERAL MOTORS CORP.
  30. If equipped with the RPO LS6 engine, remove the PCV valve hose (1) from the valley cover and intake manifold.
    31. Fig 15: Intake Manifold Bolts & Fuel Rail Stop Bracket
    GM490927Courtesy of GENERAL MOTORS CORP.
  31. Remove the intake manifold bolts (1) and fuel rail stop bracket (2).
  32. Position the intake manifold forward.
    33. Fig 16: MAP Sensor Vacuum Hose & MAP Sensor Electrical Connector
    GM651870Courtesy of GENERAL MOTORS CORP.
  33. Disconnect the manifold absolute pressure (MAP) sensor vacuum hose.
  34. Disconnect the MAP sensor (3) electrical connector.
    35. Fig 17: Intake Manifold
    GM639836Courtesy of GENERAL MOTORS CORP.
  35. Remove the intake manifold.
    36. Fig 18: Intake Manifold Gaskets
    GM490579Courtesy of GENERAL MOTORS CORP.
  36. Remove the intake manifold gaskets (1). Discard the old gaskets.
  37. Clean and inspect the intake manifold. Refer to Intake Manifold Cleaning and Inspection .
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