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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 - Upper >> 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.
  1. If required, install the purge solenoid valve.
    NOTE: Refer to FASTENER NOTICE .
  2. Install the EVAP canister purge solenoid valve studs. If reusing the old studs, apply threadlock GM P/N 12345382, (Canadian P/N 10953489), or equivalent to the threads.

    Tighten 

    Tighten the studs to 10 N.m (89 lb in).

    Fig 1: EVAP Canister Purge Solenoid Valve
    G02105766Courtesy of GENERAL MOTORS CORP.
  3. If required, install a NEW MAP sensor seal. Apply a small drop of clean engine oil to the seal.
  4. Install the MAP sensor.
    Fig 2: MAP Sensor & Seal
    G02105767Courtesy of GENERAL MOTORS CORP.
  5. If required, install a NEW throttle body gasket.
  6. Install the throttle body.
  7. Install the rear throttle body stud. If reusing the old stud, apply threadlock GM P/N 12345382, (Canadian P/N 10953489), or equivalent to the threads.

    Tighten 

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

    Fig 3: Throttle Body & Gasket
    G02105768Courtesy of GENERAL MOTORS CORP.
  8. If required, install a NEW O-ring seal to the PCV cover. Apply clean engine oil to the seal.
  9. Install the PCV valve cover.
    Fig 4: PCV Valve Cover & O-Ring Seal
    G02105769Courtesy of GENERAL MOTORS CORP.
  10. If required, install a NEW O-ring seal. Apply clean engine oil to the seal.
  11. Install the power brake booster vacuum fitting.
    Fig 5: Power Brake Booster Vacuum Fitting & O-Ring Seal
    G02105770Courtesy of GENERAL MOTORS CORP.
  12. Install a NEW O-ring seal to the fuel meter body.
    Fig 6: Fuel Meter Body O-Ring Seal
    G02105771Courtesy of GENERAL MOTORS CORP.
  13. Install a NEW upper intake manifold gasket.
    Fig 7: Upper Intake Manifold Gasket
    G02105772Courtesy of GENERAL MOTORS CORP.
  14. Install the intake manifold-upper.
  15. If reusing the old throttle body/intake manifold studs, apply threadlock GM P/N 12345382, (Canadian P/N 10953489), or equivalent to the threads.
  16. Install the front two throttle body studs.
  17. Install the intake manifold-upper studs.

    Tighten 

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

    Fig 8: Intake Manifold & Studs
    G02105773Courtesy of GENERAL MOTORS CORP.
  18. Install the accelerator cable bracket.
  19. Install the accelerator cable bracket nuts.

    Tighten 

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

    Fig 9: Accelerator Cable Bracket & Nuts
    G02105774Courtesy of GENERAL MOTORS CORP.
  20. Connect the power brake booster vacuum hose to the vacuum fitting.
    Fig 10: Power Brake Booster Vacuum Hose & Vacuum Fitting
    G02105775Courtesy of GENERAL MOTORS CORP.
  21. Install the PCV valve hose to the valve cover and rocker cover.
    Fig 11: PCV Valve Hose
    G02105776Courtesy 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 12: Engine Wiring Harness Rear Bracket & Nut
    G02105777Courtesy 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 13: Engine Wiring Harness Ground Nut & Wire
    G02105778Courtesy 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 14: Engine Wiring Harness Bracket & Nuts
    G02105779Courtesy of GENERAL MOTORS CORP.
  28. Connect the EVAP canister harness to the purge solenoid valve.
    Fig 15: EVAP Canister Harness & Purge Solenoid Valve
    G02105780Courtesy of GENERAL MOTORS CORP.
  29. Connect the following electrical connectors:
    • The EVAP canister purge solenoid valve (1)
    • The MAP sensor (2)
    Fig 16: EVAP Canister Purge Solenoid Valve & MAP Sensor
    G02105781Courtesy 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 17: TP Sensor, IAC Motor, Control Port Injector Module & Wiring Harness Clip Bolt
    G02105782Courtesy 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 18: Accelerator Control Cable, Bracket & Nuts
    G02105783Courtesy 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 19: A/C Compressor Clutch, Switch & Wiring Harness Clip
    G02105784Courtesy of GENERAL MOTORS CORP.
  37. Install the accelerator cable to the accelerator control cable bracket.
    Fig 20: Accelerator Cable & Bracket
    G02105785Courtesy of GENERAL MOTORS CORP.
  38. Install the accelerator cable to the throttle body lever.
    Fig 21: Accelerator Cable & Throttle Body Lever
    G02105786Courtesy 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.
  41. Install the fuel pipes/hoses. Refer to FUEL HOSES & PIPES .
    Fig 22: Cruise Control Cable & Accelerator Control Cable Bracket
    G02105787Courtesy of GENERAL MOTORS CORP.
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