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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 >> Upper 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: View Of Upper Intake Manifold & Lower Intake Manifold
    GM1608816Courtesy of GENERAL MOTORS CORP.
  1. Install NEW upper to lower intake manifold gaskets.
  2. Install the upper intake manifold onto the lower intake manifold.
  3. Apply threadlock to the upper intake manifold bolts/stud threads. Refer to Adhesives, Fluids, Lubricants, and Sealers .
    4. CAUTION: Refer to Fastener Caution .
  4. Install the upper intake manifold bolts and stud and tighten to 25 N.m (18 lb ft).
  5. Install the intake manifold cover ball stud nut to the intake manifold stud and tighten the nut to 5 N.m (44 lb in).
  6. Install the ignition coil bracket (to intake manifold) bolts and tighten to 25 N.m (18 lb ft).
    7. Fig 2: View Of MAP Sensor Seal & Upper Intake Manifold
    GM1608814Courtesy of GENERAL MOTORS CORP.
  7. Install the MAP sensor and bracket.
  8. Install the MAP sensor bracket bolts and tighten to 25 N.m (18 lb ft).
    9. Fig 3: Identifying EVAP Canister Purge Valve
    GM1608810Courtesy of GENERAL MOTORS CORP.
  9. Install the EVAP canister purge solenoid valve.
  10. Install the EVAP canister purge solenoid valve bolt and tighten to 16 N.m (12 lb ft).
    11. Fig 4: Identifying Throttle Body, Throttle Body Seal & Intake Manifold
    GM1608805Courtesy of GENERAL MOTORS CORP.
  11. Inspect the throttle body seal for damage, replace as necessary.
  12. Apply threadlock to the throttle body bolts/studs threads. Refer to Adhesives, Fluids, Lubricants, and Sealers .
  13. Position the throttle body gasket and throttle body to the intake.
  14. Install the throttle body bolts and nuts and tighten to 10 N.m (89 lb in).
    15. Fig 5: View Of Left Side Spark Plug Wires
    GM1608802Courtesy of GENERAL MOTORS CORP.
  15. Install the left side spark plug wires.
  16. Engage the spark plug wire retainer clips to the intake manifold bracket and the heater inlet/outlet hose/pipe bracket.
  17. Connect the left side spark plug wires to the ignition coil.
  18. Connect the left side spark plug wires to the spark plugs.
  19. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
    20. Fig 6: View Of EVAP Canister Purge Solenoid Electrical Connector
    GM1608290Courtesy of GENERAL MOTORS CORP.
  20. Connect the EVAP canister purge solenoid electrical connector (1).
  21. Connect the chassis EVAP line quick connect fitting to the purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service .
  22. Connect the ETC electrical connector (2).
    23. Fig 7: View Of MAP Sensor Electrical Connector
    GM1608869Courtesy of GENERAL MOTORS CORP.
  23. Connect the MAP sensor electrical connector (1).
    24. Fig 8: Coolant Inlet And Outlet Hoses/Pipes
    GM1608325Courtesy of GENERAL MOTORS CORP.
  24. Position the hoses/pipes.
  25. Install the heater inlet and outlet hoses/pipes to the engine pipes and the throttle body studs.
  26. Install the heater inlet and outlet hose/pipe clamp nuts to the throttle body studs and tighten the nuts to 10 N.m (89 lb in).
  27. Position the heater inlet and outlet hose/pipe clamps at the engine pipes.
    28. Fig 9: View Of Brake Booster Vacuum Hose & Intake Manifold
    GM1608820Courtesy of GENERAL MOTORS CORP.
  28. Install the vacuum hose to the intake manifold.
    29. Fig 10: Locating PCV Foul Air Tube
    GM1608801Courtesy of GENERAL MOTORS CORP.
  29. Install the PCV foul air tube. Refer to Plastic Collar Quick Connect Fitting Service .
    30. Fig 11: View Of PCV Tube & Air Inlet Duct
    GM1608799Courtesy of GENERAL MOTORS CORP.
  30. Install the PCV fresh air tube. Refer to Plastic Collar Quick Connect Fitting Service .
  31. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill Without HP5)Cooling System Draining and Filling (GE 47716 Fill Without HP5) .
  32. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  33. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .
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