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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 >> Removal Procedure

Removal 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.
IMPORTANT:
  • The intake manifold may be removed as an assembly. Do not remove the specific intake manifold components unless component service is required.
  • It is not necessary to remove the upper intake manifold in order to remove the lower intake manifold.
  • Do not allow dirt or debris to enter the fuel system. Ensure that the ends of the fuel system are properly sealed.
  • Do not disassemble the central sequential fuel injection (SFI) unit, unless service is required.
  1. Drain the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM .
  2. Remove the fuel pipes/hoses. Refer to FUEL HOSES & PIPES .
  3. Remove the distributor. Refer to DISTRIBUTOR .
  4. Disconnect the evaporative emission (EVAP) canister harness from the purge solenoid valve.
    5. Fig 1: Evaporative Emission (EVAP) Canister Harness & Purge Solenoid Valve
    G02105788Courtesy of GENERAL MOTORS CORP.
  5. Remove the heater hose clamp (1).
    Fig 2: Heater Hose Clamp
    G02105789Courtesy of GENERAL MOTORS CORP.
  6. Open the heater outlet hose clamp and remove the hose from the intake manifold.
    Fig 3: Heater Outlet Hose & Clamp
    G02105790Courtesy of GENERAL MOTORS CORP.
  7. Open the heater inlet hose clamp and remove the hose from the water pump.
  8. Reposition the heater inlet and outlet hoses.
    Fig 4: Heater Inlet Hose
    G02105791Courtesy of GENERAL MOTORS CORP.
  9. Disconnect the cruise control cable from the throttle body lever, if equipped.
  10. Remove the cruise control cable from the accelerator control cable bracket, if equipped.
    Fig 5: Cruise Control Cable & Accelerator Control Bracket
    G02105792Courtesy of GENERAL MOTORS CORP.
  11. Remove the accelerator cable from the throttle body lever.
    Fig 6: Accelerator Cable & Throttle Body Lever
    G02105793Courtesy of GENERAL MOTORS CORP.
  12. Remove the accelerator cable from the accelerator control cable bracket.
    Fig 7: Accelerator Cable & Accelerator Control Cable Bracket
    G02105794Courtesy of GENERAL MOTORS CORP.
  13. Disconnect the following electrical connectors:
    • The air conditioning (A/C) compressor clutch (1), if equipped
    • The A/C pressure switch (4), if equipped
  14. Remove the engine wiring harness clip (3) from the accelerator control cable bracket.
    Fig 8: A/C Compressor Clutch & Pressure Switch Electrical Connectors & Wiring Harness Clip
    G02105795Courtesy of GENERAL MOTORS CORP.
  15. Remove the accelerator control cable bracket nuts.
  16. Remove the accelerator control cable bracket with the cables attached, from the throttle body.
  17. Reposition and secure the bracket and cables out of the way.
    Fig 9: Accelerator Control Cable Bracket & Nuts
    G02105796Courtesy of GENERAL MOTORS CORP.
  18. Disconnect the following electrical connectors:
    • The throttle position (TP) sensor (1)
    • The idle air control (IAC) motor (2)
    • The control port injector module (3)
  19. Remove the engine wiring harness clip bolt (4).
    Fig 10: TP Sensor, IAC Motor & Control Port Injector Module Electrical Connectors
    G02105797Courtesy of GENERAL MOTORS CORP.
  20. Disconnect the following electrical connectors:
    • The evaporative emission (EVAP) canister purge solenoid valve (1)
    • The manifold absolute pressure (MAP) sensor (2)
    Fig 11: EVAP Canister Purge Solenoid Valve & MAP Sensor Electrical Connectors
    G02105798Courtesy of GENERAL MOTORS CORP.
  21. Remove the engine wiring harness bracket nuts.
  22. Remove the engine wiring harness bracket.
    Fig 12: Engine Wiring Harness Bracket & Nuts
    G02105799Courtesy of GENERAL MOTORS CORP.
  23. Remove the engine wiring harness ground nut and ground wire (4) from the rear of the right cylinder head.
    Fig 13: Engine Wiring Harness Ground Nut & Ground Wire
    G02105800Courtesy of GENERAL MOTORS CORP.
  24. Remove the engine wiring harness rear bracket nut at the EVAP canister purge solenoid valve.
  25. Remove the stud holding the engine wiring harness bracket.
  26. Reposition the engine wiring harness with the bracket aside.
    Fig 14: Engine Wiring Harness Rear Bracket & Nut
    G02105801Courtesy of GENERAL MOTORS CORP.
  27. Remove the PCV valve hose from the valve cover and rocker cover.
    Fig 15: PCV Valve Hose
    G02105802Courtesy of GENERAL MOTORS CORP.
  28. Disconnect the power brake booster vacuum hose from the vacuum fitting.
    Fig 16: Power Brake Booster Vacuum Hose & Vacuum Fitting
    G02105803Courtesy of GENERAL MOTORS CORP.
  29. Reposition the radiator inlet hose clamps.
  30. Remove the radiator inlet hose from the thermostat housing.
    Fig 17: Radiator Inlet Hose
    G02105804Courtesy of GENERAL MOTORS CORP.
  31. Reposition the water pump inlet hose clamps.
  32. Remove the water pump inlet hose.
    Fig 18: Water Pump Inlet Hose & Clamps
    G02105805Courtesy of GENERAL MOTORS CORP.
  33. In order to remove the front intake manifold bolt, perform the following:
    1. 33.1. Remove the drive belt. Refer to Drive Belt Replacement .
    2. 33.2. Loosen the power steering (P/S) pump rear bracket nut.
    3. 33.3. Remove the P/S pump rear bracket front nut.
    4. 33.4. Remove the bolts and the nut for the P/S pump bracket.
    5. 33.5. Leave the A/C compressor, if equipped, and the P/S pump on the bracket.
    6. 33.6. Slide the P/S pump bracket forward to access the front intake manifold bolt.
    Fig 19: Front Intake Manifold Bolt
    G02105806Courtesy of GENERAL MOTORS CORP.
  34. Remove the intake manifold-lower bolts.
  35. Remove the intake manifold.
  36. Remove and discard the intake manifold gaskets.
  37. Clean and inspect the intake manifold-lower, if necessary. Refer to Intake Manifold Cleaning and Inspection .
    Fig 20: Intake Manifold & Bolts
    G02105807Courtesy of GENERAL MOTORS CORP.
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