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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1618 (Engine Mechanical - 4.3L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Intake Manifold Replacement - Lower >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2003 GMC Sierra and 2003 Chevrolet Silverado. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Apply the proper amount of the sealant when assembling this component. Excessive use of the sealant can prohibit the component from sealing properly. A component that is not sealed properly can leak leading to extensive engine damage.
  1. Apply a 4.0 mm (0.157 in) patch of adhesive GM P/N 12346141, (Canadian P/N 10953433), or equivalent to the cylinder head side of the intake manifold gasket at each end.
    IMPORTANT: The intake manifold gasket must be installed while the adhesive is still wet to the touch.
  2. Install the intake manifold gasket onto the cylinder head. Use the gasket locating pins in order to properly seat the gasket.
    Fig 1: Cylinder Head Side Of Intake Manifold Gasket & Locating Pins
    G02105808Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The intake manifold must be installed and the fasteners tightened while the adhesive is still wet to the touch.
  3. Apply a 5 mm (0.197 in) bead of adhesive GM P/N 12346141, (Canadian P/N 10953433), or equivalent to the front top of the engine block.
  4. Extend the adhesive bead 13 mm (0.50 in) up onto each intake manifold gasket.
    Fig 2: Apply Bead Of Adhesive To Front Top Of Engine Block
    G02105809Courtesy of GENERAL MOTORS CORP.
  5. Apply a 5 mm (0.197 in) bead of adhesive GM P/N 12346141, (Canadian P/N 10953433), or equivalent to the rear top of the engine block.
  6. Extend the adhesive bead 13 mm (0.50 in) up onto each intake manifold gasket.
    Fig 3: Apply Bead Of Adhesive To Rear Top Of Engine Block
    G02105810Courtesy of GENERAL MOTORS CORP.
  7. Install the intake manifold.
  8. If reusing the old fasteners, apply threadlock GM P/N 12345382, (Canadian P/N 10953489), or equivalent to the threads of the intake manifold-lower bolts.
  9. Install the intake manifold-lower bolts.
    Fig 4: Intake Manifold & Bolts
    G02105811Courtesy of GENERAL MOTORS CORP.
    NOTE: Proper lower intake manifold fastener tightening sequence and torque is critical. Always follow the tightening sequence, and torque the intake manifold bolts using the 3 step method. Failing to do so may distort the crankshaft bearing bore alignment and cause damage to the crankshaft bearings.
    NOTE: Refer to FASTENER NOTICE .
  10. Tighten the intake manifold-lower bolts in the sequence shown.

    Tighten 

    1. 10.1. Tighten the bolts a first pass to 3 N.m (27 lb in).
    2. 10.2. Tighten the bolts a second pass to 12 N.m (106 lb in).
    3. 10.3. Tighten the bolts a final pass to 15 N.m (11 lb ft).
    Fig 5: Tightening Sequence For Intake Manifold Lower Bolts
    G02105812Courtesy of GENERAL MOTORS CORP.
  11. Slide the P/S pump bracket rearward.
  12. Install the bolts and the nut for the P/S pump bracket.
  13. Install the P/S pump rear bracket front nut.
  14. Tighten the P/S pump rear bracket nut.

    Tighten 

    Tighten the bolts and nuts to 41 N.m (30 lb ft).

  15. Install the drive belt. Refer to Drive Belt Replacement .
    Fig 6: Power Steering Pump Bracket, Bolts & Nut
    G02105813Courtesy of GENERAL MOTORS CORP.
  16. Install the water pump inlet hose.
  17. Position the water pump inlet hose clamps.
    Fig 7: Water Pump Inlet Hose & Clamps
    G02105814Courtesy of GENERAL MOTORS CORP.
  18. Install the radiator inlet hose to the thermostat housing.
  19. Position the radiator inlet hose clamps.
    Fig 8: Radiator Inlet Hose
    G02105815Courtesy of GENERAL MOTORS CORP.
  20. Connect the power brake booster vacuum hose to the vacuum fitting.
    Fig 9: Power Brake Booster Vacuum Hose & Vacuum Fitting
    G02105816Courtesy of GENERAL MOTORS CORP.
  21. Install the PCV valve hose to the valve cover and rocker cover.
    Fig 10: PCV Valve Hose
    G02105817Courtesy of GENERAL MOTORS CORP.
  22. Position the engine wiring harness and bracket.
  23. Install the engine wiring harness bracket stud.

    Tighten 

    Tighten the stud to 25 N.m (18 lb ft).

  24. Install the engine wiring harness rear bracket nut at the EVAP canister purge solenoid valve.

    Tighten 

    Tighten the nut to 9 N.m (80 lb in).

    Fig 11: Engine Wiring Harness Bracket, Stud & Nut
    G02105818Courtesy of GENERAL MOTORS CORP.
  25. Install the engine wiring harness ground nut and ground wire (4) to the rear of the right cylinder head.

    Tighten 

    Tighten the nut to 16 N.m (12 lb ft).

    Fig 12: Engine Wiring Harness Ground Nut & Ground Wire
    G02105819Courtesy of GENERAL MOTORS CORP.
  26. Install the engine wiring harness bracket.
  27. Install the engine wiring harness bracket nuts.

    Tighten 

    Tighten the nuts to 12 N.m (106 lb in).

    Fig 13: Engine Wiring Harness Bracket & Nuts
    G02105820Courtesy of GENERAL MOTORS CORP.
  28. Connect the EVAP canister harness to the purge solenoid valve.
    Fig 14: EVAP Canister Harness & Purge Solenoid Valve
    G02105821Courtesy of GENERAL MOTORS CORP.
  29. Connect the following electrical connectors:
    • The EVAP canister purge solenoid valve (1)
    • The MAP sensor (2)
    Fig 15: Connecting EVAP Canister Purge Solenoid Valve And MAP Sensor
    G02105822Courtesy of GENERAL MOTORS CORP.
  30. Connect the following electrical connectors:
    • The TP sensor (1)
    • The IAC motor (2)
    • The control port injector module (3)
  31. Install the engine wiring harness clip bolt (4).

    Tighten 

    Tighten the bolt to 9 N.m (80 lb in).

    Fig 16: TP Sensor, IAC Motor, Control Port Injector Module & Wiring Harness Clip Bolt
    G02105823Courtesy of GENERAL MOTORS CORP.
  32. Position the bracket and cables.
  33. Install the accelerator control cable bracket with the cables attached, to the throttle body.
  34. Install the accelerator control cable bracket nuts.

    Tighten 

    Tighten the nuts to 9 N.m (80 lb in).

    Fig 17: Accelerator Control Cable, Bracket & Nuts
    G02105824Courtesy of GENERAL MOTORS CORP.
  35. Connect the following electrical connectors:
    • The A/C compressor clutch (1), if equipped
    • The A/C pressure switch (4), if equipped
  36. Install the engine wiring harness clip (3) to the accelerator control cable bracket.
    Fig 18: A/C Compressor Clutch, A/C Pressure Switch & Wiring Harness Clip
    G02105825Courtesy of GENERAL MOTORS CORP.
  37. Install the accelerator cable to the accelerator control cable bracket.
    Fig 19: Accelerator Cable & Accelerator Control Cable Bracket
    G02105826Courtesy of GENERAL MOTORS CORP.
  38. Install the accelerator cable to the throttle body lever.
    Fig 20: Installing Accelerator Cable & Throttle Body Lever
    G02105827Courtesy of GENERAL MOTORS CORP.
  39. Install the cruise control cable to the accelerator control cable bracket, if equipped.
  40. Connect the cruise control cable to the throttle lever, if equipped.
    Fig 21: Cruise Control Cable & Accelerator Control Cable Bracket
    G02105828Courtesy of GENERAL MOTORS CORP.
  41. Position the heater inlet and outlet hoses.
  42. Open the heater inlet hose clamp and install the hose to the water pump.
    Fig 22: Heater Inlet Hoses
    G02105829Courtesy of GENERAL MOTORS CORP.
  43. Open the heater out let hose clamp and install the hose to the intake manifold.
    Fig 23: Heater Outlet Hose & Clamp
    G02105830Courtesy of GENERAL MOTORS CORP.
  44. Install the heater hose clamp (1).
  45. Install the fuel pipes/hoses. Refer to FUEL HOSES & PIPES .
  46. Install the distributor. Refer to DISTRIBUTOR .
  47. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM .
    Fig 24: Heater Hose Clamp
    G02105831Courtesy of GENERAL MOTORS CORP.
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