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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 905 (Engine Mechanical - 2.2L (LN2)) >> Repair Instructions >> On-Vehicle Repair Instructions >> Intake Manifold Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2003 GMC Sonoma and 2003 Chevrolet S10 Pickup. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the fuel rail if removed .
  2. Install the throttle body if removed.
  3. Install the intake manifold gasket.
  4. Install the intake manifold.
    Fig 1: Installing Intake Manifold
    G01976963Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  5. Install the intake manifold bolts.

    Tighten 

    Tighten the bolts in sequence to 24 N.m (17 lb ft).

    Fig 2: Identifying Tightening Sequence Intake Manifold Bolts
    G01976964Courtesy of GENERAL MOTORS CORP.
  6. Install the engine wire harness bracket to the rear of the engine using the following procedure:
    1. 6.1. Slide the bracket over the bolt at the rear of the cylinder head.
    2. 6.2. Install the 2 bolts that secure the bracket to the valve rocker arm cover.
  7. Tighten the bolts in the following order:

    Tighten 

    1. 7.1. Tighten the 2 bolts to the valve rocker arm cover to 10 N.m (89 lb in).
    2. 7.2. Tighten the bolt at the rear of the cylinder head to 25 N.m (18 lb ft).
      Fig 3: Installing Engine Wire Harness Bracket To Rear Of Engine
      G01976965Courtesy of GENERAL MOTORS CORP.
  8. Working through the wheelhouse, install the generator rear brace.
  9. Install the nuts holding the brace to the intake manifold stud and the stud on the engine.
  10. Install the bolt holding the brace to the rear of the generator.

    Tighten 

    Tighten the generator rear brace nuts and bolts to 25 N.m (18 lb ft).

    Fig 4: Installing Generator Rear Brace
    G01976966Courtesy of GENERAL MOTORS CORP.
  11. Position the spark plug wire harness.
  12. Install the spark plug wire harness retainer on the thermostat assembly.
  13. Install the spark plug wires to the spark plugs. Refer to SPARK PLUGS in Service & Adjustment Specifications - 2.2L in Engine Performance.
  14. Install the accelerator control cable to the throttle body.
  15. Install the cruise control cable to the throttle body. Refer to CRUISE CONTROL CABLE REPLACEMENT (2.2L) in Cruise Control.
  16. Connect the fuel hose to the fuel rail.
    Fig 5: Installing Spark Plug Wire Harness Retainer On Thermostat Assembly
    G01976967Courtesy of GENERAL MOTORS CORP.
  17. Install the bolt holding the EVAP emission canister purge harness and if equipped the transmission fluid fill tube.

    Tighten 

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

  18. Install the nut holding the engine wiring harness the clip and the negative battery cable clip to the intake manifold.

    Tighten 

    Tighten the engine wiring harness clip nut to 10 N.m (89 lb in).

  19. Install the nut holding the engine wiring harness clip to the intake manifold rear lower stud.

    Tighten 

    Tighten the engine wiring harness clip nut to 30 N.m (89 lb in).

    Fig 6: Installing Nut Holding Engine Wiring Harness Clip To Intake Manifold
    G01976968Courtesy of GENERAL MOTORS CORP.
  20. Connect the heating and air conditioning control vacuum source hose.
  21. Connect the EVAP emission purge tube to the throttle body.
    Fig 7: Connecting EVAP Emission Purge Tube To Throttle Body
    G01976969Courtesy of GENERAL MOTORS CORP.
  22. Position the engine wiring harness.
  23. Install the engine wiring harness to the bracket.
  24. Install the fuel injector harness electrical connector to the bracket on the valve rocker arm cover.
  25. Connect the fuel injector harness electrical connector.
    Fig 8: Installing Engine Wiring Harness To Bracket
    G01976970Courtesy of GENERAL MOTORS CORP.
  26. Connect 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 9: Connecting Electrical Connectors
      G01976971Courtesy of GENERAL MOTORS CORP.
  27. Install the right fender wheelhouse extension.
  28. Install the air cleaner outlet resonator.
    Fig 10: Installing Right Fender Wheelhouse Extension
    G01976972Courtesy of GENERAL MOTORS CORP.
  29. Install the upper fan shroud. Refer to FAN SHROUD REPLACEMENT in Engine Cooling.
  30. Connect the power brake booster vacuum hose.
  31. Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Battery.
    Fig 11: Connecting Power Brake Booster Vacuum Hose
    G01976973Courtesy of GENERAL MOTORS CORP.
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