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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 >> Removal Procedure

Removal 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. Disconnect the negative battery cable.
  2. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (L36)  or Fuel Injector Sight Shield Replacement (L67) 
  3. Remove the air cleaner intake duct.
  4. Drain the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in ENGINE COOLING .
  5. Remove the right spark plug wires from the ignition control module and reposition. Refer to SPARK PLUGS
  6. Relieve the fuel pressure. Refer to FUEL SYSTEM PRESSURE RELEASE
  7. Remove the fuel rail assembly. Refer to FUEL RAIL & INJECTORS
  8. Remove the brake booster hose from the vacuum source manifold.
  9. Remove the exhaust gas recirculation (EGR) valve wiring harness heat shield nut, bolt and the EGR heat shield.
    Fig 1: EGR Heat Shield
    G01764129Courtesy of GENERAL MOTORS CORP.
  10. Remove the throttle body support bracket upper bolt.
    Fig 2: Throttle Body Support Bracket Upper Bolt
    G01764130Courtesy of GENERAL MOTORS CORP.
  11. Disconnect the electrical connectors from the following:
    • EVAP purge solenoid
    • Throttle position (T/P) sensor
    • Idle air control (IAC) valve
    • Manifold absolute pressure (MAP) sensor
    • Mass air flow (MAP) sensor
  12. Remove the EVAP purge solenoid vacuum line from the throttle body.
  13. Remove the accelerator and the cruise control cables with the bracket from the throttle body.
  14. Remove the upper intake manifold bolts and stud.
  15. Clean the upper intake manifold bolt threads.
  16. Remove the upper intake manifold by lifting the back of the intake and sliding the manifold forward from the throttle body support bracket.
    Fig 3: Upper Intake Manifold
    G01764131Courtesy of GENERAL MOTORS CORP.
  17. Remove the upper-to-lower intake manifold carrier gasket from the upper intake manifold.
  18. If the upper intake manifold is being replaced, remove the following:
    • Throttle body
    • Manifold absolute pressure (MAP) sensor
    • Positive crankcase ventilation (PCV) valve
    • Vacuum source manifold
    Fig 4: Upper-To-Lower Intake Manifold Carrier Gasket
    G01764132Courtesy of GENERAL MOTORS CORP.
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