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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 >> Removal Procedure

Removal 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. Disconnect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE .
  2. Remove the upper fan shroud. Refer to FAN SHROUD REPLACEMENT .
  3. Disconnect the power brake booster vacuum hose.
  4. Remove the air cleaner outlet resonator.
    Fig 1: Power Brake Booster Vacuum Hose
    G01658850Courtesy of GENERAL MOTORS CORP.
  5. Disconnect 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 2: IAC Motor, MAP Sensor, TP Sensor & ECT Sensor Electrical Connectors
    G01658851Courtesy of GENERAL MOTORS CORP.
  6. Disconnect the fuel injector harness electrical connector.
  7. Remove the fuel injector harness electrical connector from the bracket on the valve rocker arm cover.
  8. Remove the engine wiring harness from the bracket.
  9. Move and secure the engine wiring harness out of the way.
    Fig 3: Fuel Injector Harness Electrical Connector
    G01658852Courtesy of GENERAL MOTORS CORP.
  10. Disconnect the heating and air conditioning control vacuum source hose.
  11. Disconnect the EVAP emission purge tube from the throttle body.
    Fig 4: Heating & Air Conditioning Control Vacuum Source Hose And EVAP Emission Purge Tube
    G01658853Courtesy of GENERAL MOTORS CORP.
  12. Remove the bolt holding the EVAP emission canister purge harness and if equipped the transmission fluid fill tube.
  13. Remove the nut holding the engine wiring harness clip to the intake manifold.
  14. Remove the nut holding the engine wiring harness clip to the intake manifold rear lower stud.
    15. Fig 5: EVAP Emission Canister Purge Harness & Nuts
    G01658854Courtesy of GENERAL MOTORS CORP.
  15. Disconnect the fuel hose from the fuel rail.
  16. Remove the accelerator control cable from the throttle body.
  17. Remove the cruise control cable from the throttle body. Refer to CRUISE CONTROL CABLE REPLACEMENT (4.3L) or CRUISE CONTROL CABLE REPLACEMENT (2.2L) .
  18. Remove the spark plug wires from the spark plugs.
  19. Remove the spark plug wire harness retainer from the thermostat assembly and set aside the spark plug wire harness.
    Fig 6: Spark Plug Wire Harness Retainer
    G01658855Courtesy of GENERAL MOTORS CORP.
  20. Remove the right fender wheelhouse extension.
    Fig 7: Right Fender Wheelhouse Extension
    G01658856Courtesy of GENERAL MOTORS CORP.
  21. Working through the wheelhouse, remove the generator rear brace from the engine.
    • Remove the nuts holding the brace to the intake stud and the engine block.
    • Remove the bolt holding the brace to the rear of the generator.
    Fig 8: Generator Rear Brace, Nuts & Bolt
    G01658857Courtesy of GENERAL MOTORS CORP.
  22. Remove the engine wiring harness bracket at the back of the engine using the following procedure:
    1. 22.1. Loosen the bolt at the rear of the cylinder head.
    2. 22.2. Remove the 2 bolts that secure the bracket to the valve rocker arm cover.
    3. 22.3. Slide the bracket off of the bolt at the rear of the cylinder head.
    Fig 9: Engine Wiring Harness Bracket & Bolts
    G01658858Courtesy of GENERAL MOTORS CORP.
  23. Remove the intake manifold bolts.
  24. Remove the intake manifold nuts.
  25. Remove the fuel rail bracket.
  26. Remove the intake manifold.
  27. If replacing the intake manifold remove the following:
    Fig 10: Intake Manifold & Bolts
    G01658859Courtesy of GENERAL MOTORS CORP.
  28. Clean the intake manifold mating surfaces.
  29. Inspect the intake manifold for damage.
  30. Inspect the intake manifold for cracks near compression limiters.
  31. Inspect the crankcase ventilation passages in the intake manifold face for blockage and clean as necessary.
  32. Replace the intake manifold as necessary.
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