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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 598 (Engine Mechanical - 3.8L (On-Vehicle)) >> Repair Instructions >> Intake Manifold Replacement - Upper >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2002 Buick Regal. However, it is still accessible from the selected car via links, so may be relevant.
  1. If the manifold was replaced install the following:
    • Vacuum source manifold
    • Positive crankcase ventilation (PCV) valve
    • Manifold absolute pressure (MAP) sensor
    • Throttle body
  2. Install the upper-to-lower intake manifold carrier gasket to the upper intake manifold.
    Fig 1: Upper-To-Lower Intake Manifold Carrier Gasket
    G01764133Courtesy of GENERAL MOTORS CORP.
  3. Carefully place the upper intake manifold onto the lower intake manifold. Ensure that the alignment pins in the upper intake manifold align with the holes in the lower intake manifold.
  4. Install the upper intake manifold.
  5. Apply thread lock compound GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the bolt threads before assembly.
    Fig 2: Upper Intake Manifold
    G01764134Courtesy of GENERAL MOTORS CORP.
  6. Install the upper intake manifold bolts (1-10).

    Tighten: 

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

    Fig 3: Upper Intake Manifold Bolts Tightening Sequence
    G01764135Courtesy of GENERAL MOTORS CORP.
  7. Install the accelerator and the cruise control cables with the bracket to the throttle body.
  8. Install the EVAP purge solenoid vacuum line to the throttle body.
  9. Connect the electrical connectors to the following:
    • Mass air flow (MAP) sensor
    • Manifold absolute pressure (MAP) sensor
    • Idle air control (IAC) valve
    • Throttle position (T/P) sensor
    • EVAP purge solenoid
  10. Install the throttle body upper support bracket bolt.

    Tighten: 

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

    Fig 4: Throttle Body Upper Support Bracket
    G01764136Courtesy of GENERAL MOTORS CORP.
  11. Install the EGR valve wiring harness heat shield, nut and bolt.

    Tighten: 

    Tighten the nut and the bolt to 10 N.m (89 lb in) 

    Fig 5: EGR Valve Heat Shield
    G01764137Courtesy of GENERAL MOTORS CORP.
  12. Install the brake booster hose to the vacuum source manifold.
  13. Install the fuel rail assembly. Refer to FUEL RAIL & INJECTORS
  14. Install the right spark plug wires to the ignition control module. Refer to SPARK PLUGS
  15. Install the air cleaner intake duct.
  16. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (L36)  or Fuel Injector Sight Shield Replacement (L67) 
  17. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in ENGINE COOLING .
  18. Connect the negative battery cable.
  19. Inspect for fluid or vacuum leaks.
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