LEMON Manuals: Even more car manuals for everyone
Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 428 (Engine Mechanical - 8.1L V8) >> Removal & Installation >> Intake Manifold >> Installation

Intake Manifold: Installation

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2003 GMC Yukon XL, 2003 GMC Sierra, 2003 GMC Cab & Chassis Sierra, 2003 Chevrolet Suburban, and 2003 Chevrolet Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. If replacing intake manifold, see INTAKE MANIFOLD  under OVERHAUL.
  2. Install splash shield.
  3. Ensure splash shield snap fits between the cylinder heads.
  4. Install NEW intake manifold end seals.
  5. Install NEW intake manifold side gaskets onto the cylinder heads.
  6. Ensure intake manifold gasket tabs align with the hole in the head gasket.
  7. Ensure intake manifold gasket tabs align with the slot in the intake manifold end seals.
  8. Install intake manifold gaskets to the cylinder head with "THIS SIDE UP" stamp facing up.
  9. Install intake manifold. See Fig 7.
  10. Apply Threadlock (12345382) to a minimum of 8 threads of intake manifold bolts.
  11. Install intake manifold bolts. See Fig 7.
  12. Tighten intake manifold bolts in sequence shown, using 4 passes. Tighten intake manifold bolts to specification. See TORQUE SPECIFICATIONS .
  13. Install fuel rail. See Fig 6.
  14. Install fuel rail studs. Tighten fuel rail studs to specification. See TORQUE SPECIFICATIONS .
  15. Install fuel pressure regulator vacuum hose.
  16. Install EGR valve pipe gasket.
  17. Position EGR pipe.
  18. Install EGR pipe bolts at EGR adapter. Tighten EGR pipe bolts to specification. See TORQUE SPECIFICATIONS .
  19. Connect EGR valve harness connector. See Fig 5.
  20. Install the bypass valve vacuum hose to the intake manifold.
  21. Position engine harness over engine compartment.
  22. Connect the generator, injector harness, ignition coil harness, TP sensor & ECT sensor, and purge valve solenoid harness connector. See Fig 4.
  23. Install the CPA retainer at the ignition coil harness.
  24. Install engine harness bolt and studs. Tighten engine harness bolt to specification. Tighten engine harness studs to specification. See TORQUE SPECIFICATIONS .
  25. Connect MAP sensor, ignition coil harness and ECT sensor harness connector. See Fig 3.
  26. Position engine harness branch over the top of the engine.
  27. Connect the pressure cycling switch, surge tank switch, and MAF sensor connector. See Fig 2
  28. Connect engine harness clip to wheelhouse splash shield.
  29. Connect engine harness clips to studs on front of dash.
  30. Connect fuel feed and return pipes.
  31. Install engine sight shield bracket and nuts. Tighten sight shield bracket nuts to specification. See TORQUE SPECIFICATIONS .
  32. Install sight shield to bracket.
  33. Tighten intake manifold sight shield bolt to specification. See TORQUE SPECIFICATIONS .
  34. Install air cleaner outlet duct.
  35. Tighten clamps at throttle body and air cleaner. Tighten air cleaner outlet duct clamp to specification. See TORQUE SPECIFICATIONS .
Fig 1: Identifying Intake Manifold Components
G00277907Courtesy of GENERAL MOTORS CORP.
Fig 2: Locating MAF Sensor, Pressure Cycling Switch & Surge Tank Switch Harness Connectors
G00277887Courtesy of GENERAL MOTORS CORP.
Fig 3: Locating ECT Sensor, Ignition Coil & MAP Sensor Harness Connectors
G00277888Courtesy of GENERAL MOTORS CORP.
Fig 4: Locating Electronic Throttle Control, Generator, Injector Harness, Injector Coil, Purge Valve Solenoid & TP Sensor Harness Connectors
G00277889Courtesy of GENERAL MOTORS CORP.
Fig 5: Locating EGR Valve Harness Connector
G00277890Courtesy of GENERAL MOTORS CORP.
Fig 6: Removing Fuel Rail Assembly
G00277891Courtesy of GENERAL MOTORS CORP.
Fig 7: Removing Intake Manifold & Intake Manifold Bolt Tightening Sequence
G00277892Courtesy of GENERAL MOTORS CORP.
scientia non olet · About LEMON Manuals