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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 432 (Engine Mechanical - 2.2L (On-Vehicle)) >> Repair Instructions >> Intake Manifold Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2002 GMC Sonoma and 2002 Chevrolet S10 Pickup. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the fuel rail if removed.
  2. Install the throttle body if removed. Refer to THROTTLE BODY .
  3. Install the intake manifold gasket.
  4. Install the intake manifold.
    Fig 1: Intake Manifold & Bolts
    G01658860Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to FASTENER NOTICE .
  5. Install the intake manifold bolts.

    Tighten 

    Tighten the bolts in sequence to 24 N.m (17 lb ft).

    Fig 2: Intake Manifold Bolts Tightening Sequence
    G01658861Courtesy of GENERAL MOTORS CORP.
  6. Install the engine wire harness bracket to the rear of the engine using the following procedure:
    1. 6.1. Slide the bracket over the bolt at the rear of the cylinder head.
    2. 6.2. Install the 2 bolts that secure the bracket to the valve rocker arm cover.
  7. Tighten the bolts in the following order:

    Tighten 

    1. 7.1 Tighten the 2 bolts to the valve rocker arm cover to 10 N.m (89 lb in).
    2. 7.2 Tighten the bolt at the rear of the cylinder head to 25 N.m (18 lb ft).
    Fig 3: Engine Wire Harness Bracket & Bolts
    G01658862Courtesy of GENERAL MOTORS CORP.
  8. Working through the wheelhouse, install the generator rear brace.
  9. Install the nuts holding the brace to the intake manifold stud and the stud on the engine.
  10. Install the bolt holding the brace to the rear of the generator.

    Tighten 

    Tighten the generator rear brace nuts and bolts to 25 N.m (18 lb ft).

    Fig 4: Generator Rear Brace, Nuts & Bolt
    G01658863Courtesy of GENERAL MOTORS CORP.
  11. Position the spark plug wire harness.
  12. Install the spark plug wire harness retainer on the thermostat assembly.
  13. Install the spark plug wires to the spark plugs.
  14. Install the accelerator control cable to the throttle body.
  15. Install the cruise control cable to the throttle body. Refer to CRUISE CONTROL CABLE REPLACEMENT (4.3L) or CRUISE CONTROL CABLE REPLACEMENT (2.2L) .
  16. Connect the fuel hose to the fuel rail.
    Fig 5: Spark Plug Wire Harness Retainer
    G01658864Courtesy of GENERAL MOTORS CORP.
  17. Install the bolt holding the EVAP emission canister purge harness and if equipped the transmission fluid fill tube.

    Tighten 

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

  18. Install the nut holding the engine wiring harness clip and the negative battery cable clip to the intake manifold.

    Tighten 

    Tighten the engine wiring harness clip nut to 10 N.m (89 lb in).

  19. Install the nut holding the engine wiring harness clip to the intake manifold rear lower stud.

    Tighten 

    Tighten the engine wiring harness clip nut to 10 N.m (89 lb in).

    Fig 6: EVAP Emission Canister Purge Harness, Bolts & Nuts
    G01658865Courtesy of GENERAL MOTORS CORP.
  20. Connect the heating and air conditioning control vacuum source hose.
  21. Connect the EVAP emission purge tube to the throttle body.
    Fig 7: Heating & Air Conditioning Control Vacuum Source Hose And EVAP Emission Purge Tube
    G01658866Courtesy of GENERAL MOTORS CORP.
  22. Position the engine wiring harness.
  23. Install the engine wiring harness to the bracket.
  24. Install the fuel injector harness electrical connector to the bracket on the valve rocker arm cover.
  25. Connect the fuel injector harness electrical connector.
    Fig 8: Fuel Injector Harness Electrical Connector
    G01658867Courtesy of GENERAL MOTORS CORP.
  26. Connect the following electrical connectors:
    • Idle air control (IAC) motor (1)
    • Manifold absolute pressure (MAP) sensor (4)
    • Throttle position (TP) sensor (2)
    • Engine coolant temperature (ECT) sensor (3).
    Fig 9: IAC Motor, MAP Sensor, TP Sensor & ECT Sensor Electrical Connectors
    G01658868Courtesy of GENERAL MOTORS CORP.
  27. Install the right fender wheelhouse extension.
  28. Install the air cleaner outlet resonator.
    Fig 10: Right Fender Wheelhouse Extension
    G01658869Courtesy of GENERAL MOTORS CORP.
  29. Install the upper fan shroud. Refer to FAN SHROUD REPLACEMENT .
  30. Connect the power brake booster vacuum hose.
  31. Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE .
    Fig 11: Power Brake Booster Vacuum Hose
    G01658870Courtesy of GENERAL MOTORS CORP.
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