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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 870 (Engine Mechanical) >> Repair Instructions >> On-Vehicle Repair Instructions >> Intake Manifold Replacement - Lower >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2003 Pontiac Aztek and 2003 Buick Rendezvous. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the upper intake manifold. Refer to INTAKE MANIFOLD REPLACEMENT - UPPER  .
  2. Remove the engine left side valve rocker arm cover. Refer to VALVE ROCKER ARM COVER REPLACEMENT - LEFT  .
  3. Remove the engine right side valve rocker arm cover. Refer to VALVE ROCKER ARM COVER REPLACEMENT - RIGHT  .
  4. Disconnect the wiring harness from the engine coolant temperature (ECT) sensor.
    Fig 1: Disconnecting Wiring Harness From Engine Coolant Temperature Sensor
    G01500512Courtesy of GENERAL MOTORS CORP.

    Important:  Use masking tape or another appropriate method in order to identify each fuel injector wiring harness connector cylinder number.

  5. Disconnect and remove the fuel injector, manifold air pressure (MAP) and ECT wiring harness.
  6. Remove the fuel feed and return pipe from the fuel injector rail. Refer to FUEL LINE DISCONNECT FITTINGS .
    Fig 2: Disconnecting Fuel Injector, Manifold Air Pressure And ECT Wiring Harness
    G01500513Courtesy of GENERAL MOTORS CORP.
  7. Remove the fuel feed and return pipe retaining clip bolt.
  8. Remove the fuel feed and return pipe retaining clip.
    Fig 3: Removing Fuel Feed And Return Pipe Retaining Clip
    G01500514Courtesy of GENERAL MOTORS CORP.
  9. Remove the fuel injector rail bolts.
  10. Remove the fuel injector rail with the fuel injectors.

    Important:  Do NOT disconnect the power steering pipes or hoses from the power steering pump.

  11. Remove the power steering pump from the front engine cover and reposition. Refer to POWER STEERING PUMP REPLACEMENT .
  12. Disconnect the heater inlet pipe with heater hose from the lower intake manifold and reposition. Refer to HEATER PIPE REPLACEMENT - INLET .
  13. Disconnect the inlet radiator hose from the engine.
    Fig 4: Removing Fuel Injector Rail With Fuel Injectors
    G01500515Courtesy of GENERAL MOTORS CORP.
  14. Disconnect the thermostat bypass hose from the lower intake manifold pipe.
    Fig 5: Disconnecting Thermostat Bypass Hose From Lower Intake Manifold Pipe
    G01500516Courtesy of GENERAL MOTORS CORP.
  15. Remove the lower intake manifold bolts.
    Fig 6: Removing Lower Intake Manifold Bolts
    G01500517Courtesy of GENERAL MOTORS CORP.
  16. Remove the lower intake manifold.
  17. Loosen the valve rocker arms and remove the push rods. Refer to VALVE ROCKER ARM AND PUSH ROD REMOVAL  .
  18. Remove the lower intake manifold gaskets and seals.
  19. Clean the lower intake manifold gasket and seal surfaces on the cylinder heads and the engine block.
  20. Clean and inspect the lower intake manifold. Refer to INTAKE MANIFOLD CLEANING AND INSPECTION - LOWER  .
  21. If you are replacing the lower intake manifold, perform the following steps:
    Fig 7: Removing Lower Intake Manifold
    G01500518Courtesy of GENERAL MOTORS CORP.
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