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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 721 (Engine Mechanical - 8.1L (On-Vehicle)) >> Repair Instructions >> Intake Manifold Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2002 GMC Yukon XL, 2002 Chevrolet Suburban, and 2002 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Intake Manifold Splash Shield
    GM470786Courtesy of GENERAL MOTORS CORP.
  1. If replacing the intake manifold, refer to Intake Manifold Assemble (C/K/C3500HD/Medium Duty) Intake Manifold Assemble (G) in Engine Mechanical - 8.1L Unit Repair.
  2. Install the splash shield.
    3. Fig 2: Splash Shield & Cylinder Head
    GM413867Courtesy of GENERAL MOTORS CORP.
  3. Ensure the splash shield (2) snap fits between the cylinder heads (1).
    4. Fig 3: Intake Manifold End Seals
    GM470783Courtesy of GENERAL MOTORS CORP.
  4. Install NEW intake manifold end seals.
    5. Fig 4: Intake Manifold Gaskets
    GM470779Courtesy of GENERAL MOTORS CORP.
  5. Install NEW intake manifold side gaskets onto the cylinder heads.
    6. Fig 5: Intake Manifold Gasket Tabs & Head Gasket Hole
    GM470778Courtesy of GENERAL MOTORS CORP.
  6. Ensure the intake manifold gasket tabs align with the hole in the head gasket.
  7. Ensure the intake manifold gasket tabs align with the slot in the intake manifold end seals.
    8. Fig 6: Intake Manifold & Bolts
    GM470775Courtesy of GENERAL MOTORS CORP.
  8. Install the intake manifold gaskets to the cylinder head with THIS SIDE UP stamped facing up.
  9. Install the intake manifold.
    10. Fig 7: Intake Manifold Bolt Tightening Sequence
    GM640010Courtesy of GENERAL MOTORS CORP.
  10. Apply threadlock GM U.S. P/N 12345382, Canada P/N 10953489, or equivalent to a minimum of eight threads of the intake manifold bolts.
  11. Install the intake manifold bolts.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  12. Tighten the intake manifold bolts in sequence shown, using four passes.

    Tighten: 

    1. Tighten the intake manifold bolts to 5 N.m (44 lb in) on the first pass.
    2. Tighten the intake manifold bolts to 5 N.m (44 lb in) on the second pass.

      Inspect the intake manifold joints for signs of intake manifold shifting. Correct as required.

    3. Tighten the intake manifold bolts to 10 N.m (89 lb in) on the third pass.
    4. Tighten the intake manifold bolts to 12 N.m (106 lb in) on the final pass.

    13. Fig 8: Fuel Rail & Studs
    GM470774Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Lubricate the fuel injector O-ring seals with clean engine oil and install onto the spray tip each injector.
  13. If replacing the intake manifold, install the fuel rail.
  14. Install the fuel rail studs.

    Tighten:  Tighten the fuel rail studs to 12 N.m (106 lb in).

    15. Fig 9: Fuel Pressure Regulator Vacuum Hose
    GM470770Courtesy of GENERAL MOTORS CORP.
  15. Install the fuel pressure regulator vacuum hose.
    16. Fig 10: EGR Pipe, Bolts & Adapter
    GM635635Courtesy of GENERAL MOTORS CORP.
  16. Install the EGR valve pipe gasket.
  17. Position the EGR pipe.
  18. Install the EGR pipe bolts at the EGR adapter.

    Tighten:  Tighten the EGR pipe bolts to 30 N.m (22 lb ft).

    19. Fig 11: EGR Valve, Oil Pressure Sensor Electrical Connector & Engine Harness Ground Bolts & Straps
    GM750530Courtesy of GENERAL MOTORS CORP.
  19. Connect the EGR valve electrical connector (1).
    20. Fig 12: Bypass Valve Vacuum Hose At Intake Manifold
    GM750614Courtesy of GENERAL MOTORS CORP.
  20. Install the bypass valve vacuum hose (1) to the intake manifold.
    21. Fig 13: Locating Engine Electrical Connectors
    GM750525Courtesy of GENERAL MOTORS CORP.
  21. Position the engine harness over the engine compartment.
  22. Connect the following electrical connector:
    • Generator (1)
    • Injector harness (2)
    • Injector harness (2)
    • Ignition coil harness (3)
    • TP sensor (4)
    • ETC (5)
    • Purge valve solenoid (6)
  23. Install the CPA retainer at the ignition coil harness.
  24. Install the engine harness bolt and studs.

    Tighten: 

    • Tighten the engine harness bolt to 5 N.m (44 lb in).
    • Tighten the engine harness studs to 10 N.m (89 lb in).

    25. Fig 14: View Of Ignition Coil, ECT And MAP Sensor Electrical Connectors
    GM750529Courtesy of GENERAL MOTORS CORP.
  25. Connect the following electrical connectors:
    • MAP sensor (1)
    • Ignition coil harness (2)
    • ECT sensor (3)
    26. Fig 15: View Of MAF/IAT Sensor Electrical Connectors
    GM750582Courtesy of GENERAL MOTORS CORP.
  26. Position the engine harness branch over the top of the engine.
  27. Connect the following electrical connectors:
    • Pressure cycling switch (1)
    • Surge tank switch (2)
    • MAF sensor (3)
  28. Connect the engine harness clip to the wheelhouse splash shield.
  29. Connect the engine harness clips to the studs on the front of dash.
    30. Fig 16: Intake Manifold Sight Shield, Bolts & Retainer
    GM665445Courtesy of GENERAL MOTORS CORP.
  30. Connect the fuel feed and return pipes.
  31. Install the engine sight shield bracket (1) and nuts.

    Tighten:  Tighten the sight shield bracket nuts to 5 N.m (44 lb in).

  32. Install the sight shield to the bracket (1).
  33. Tighten the intake manifold sight shield bolt (3).

    Tighten:  Tighten the intake manifold sight shield bolt to 10 N.m (89 lb in).

    34. Fig 17: View Of Air Cleaner Outlet Duct
    GM700979Courtesy of GENERAL MOTORS CORP.
  34. Install the air cleaner outlet duct.
  35. Tighten the clamps at the throttle body and air cleaner.

    Tighten:  Tighten the air cleaner outlet duct clamp to 4 N.m (35 lb in).

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