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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1928 (Engine Mechanical - 3.5L) >> Repair Instructions - On Vehicle >> Lower Intake Manifold Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2009 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Identifying Intake Manifold Gaskets & Seals
    GM1557681Courtesy of GENERAL MOTORS CORP.
    NOTE: All gasket mating surfaces need to be free of oil and foreign material. Use cleaner to clean the surfaces. Refer to Adhesives, Fluids, Lubricants, and Sealers .
    NOTE: RTV sealer is NOT to be placed under the lower intake manifold gaskets.
  1. Install the lower intake manifold gaskets and seals.
    2. Fig 2: Identifying Valve Rocker Arm & Bolt
    GM1557679Courtesy of GENERAL MOTORS CORP.
  2. Coat the ends of the push rods using prelube. Refer to Adhesives, Fluids, Lubricants, and Sealers .
    3. NOTE: The intake valve push rods measure 146.0 mm (5.75 in) and the exhaust valve push rods measure 152.5 mm (6.0 in).
  3. Install the push rods in their original location.
  4. Coat the rocker arm friction surfaces using prelube. Refer to Adhesives, Fluids, Lubricants, and Sealers .
    5. NOTE: Shims (P/N 88894006) may be required under the valve rocker arm pedestals if reconditioning has been performed on the cylinder head or its components.
  5. Install the valve rocker arms in their original positions.
    6. CAUTION: Refer to Fastener Caution .
  6. Install the valve rocker arm bolts and tighten to 34 N.m (25 lb ft).
    7. Fig 3: View Of Lower Intake Manifold
    GM1313742Courtesy of GENERAL MOTORS CORP.
  7. With the NEW gaskets and seals in place, apply a small drop, 8-10 mm (.031-0.39 in) of RTV sealer to the 4 corners of the intake manifold to engine block joints (1). Refer to Adhesives, Fluids, Lubricants, and Sealers .
  8. Install the lower intake manifold.
    9. Fig 4: Identifying Lower Intake Manifold Tightening Sequence
    GM1557861Courtesy of GENERAL MOTORS CORP.
    CAUTION: Maximum gasket performance is achieved when using new fasteners, which contain a thread-locking patch. If the fasteners are not replaced, a thread locking chemical must be applied to the fastener threads. Failure to replace the fasteners or apply a thread-locking chemical MAY reduce gasket sealing capability.
    CAUTION: Failure to tighten vertical bolts before the diagonal bolts may cause an oil leak.
  9. Apply sealer to the lower intake manifold bolt threads. Refer to Adhesives, Fluids, Lubricants, and Sealers .
  10. Install the lower intake manifold bolts.
  11. Tighten the lower intake manifold bolts in the sequence shown.
    • Tighten the bolts (1, 2, 3, 4) in sequence to 16 N.m (12 lb ft).
    • Tighten the bolts (5, 6, 7, 8) in sequence to 25 N.m (18 lb ft).
    12. Fig 5: View Of Fuel Rail Assembly & Intake Manifold
    GM1608817Courtesy of GENERAL MOTORS CORP.
  12. Inspect the fuel rail, fuel injectors and fuel injector O-rings for damage and replace, as necessary.
  13. Lubricate the fuel injector O-rings using engine oil. Refer to Adhesives, Fluids, Lubricants, and Sealers .
  14. Install the injector nozzles into the lower intake manifold injector bores.
  15. Press on the injector rail using the palms of both hands until the injector are fully seated.
  16. Install the fuel injector rail bolts and tighten to 10 N.m (89 lb in).
  17. Connect the CMP sensor electrical connector.
  18. Connect the ECT electrical connector.
  19. Position the fuel injector harness connector bracket to the intake manifold.
  20. Install the fuel injector harness connector bracket bolt and tighten to 8 N.m (71 lb in).
    21. Fig 6: Identifying Engine Harness Clip (2) & Strut Bracket
    GM1608276Courtesy of GENERAL MOTORS CORP.
  21. Connect fuel injector inline connector.
  22. Connect the fuel feed line to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  23. Install the right valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Right Side .
  24. Install the left valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side .
  25. Install the upper intake manifold. Refer to Upper Intake Manifold Replacement .
  26. Connect the battery ground negative cable. Refer to Battery Negative Cable Disconnection and Connection .
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