LEMON Manuals: Even more car manuals for everyone
Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 906 (Engine Mechanical - 4.3L (LU3)) >> Repair Instructions >> On-Vehicle Repair Instructions >> Intake Manifold Replacement - Lower >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2003 GMC Sonoma, 2003 GMC Jimmy, 2003 Chevrolet S10 Pickup, and 2003 Chevrolet Blazer. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Apply the proper amount of the sealant when assembling this component. Excessive use of the sealant can prohibit the component from sealing properly. A component that is not sealed properly can leak leading to extensive engine damage.
  1. Apply a 4.0 mm (0.157 in) patch of adhesive GM P/N 12346141 (Canadian P/N 10953433) or equivalent to the cylinder head side of the lower intake manifold gasket at each end.

    Important:  The lower intake manifold gasket must be installed while the adhesive is still wet to the touch.

  2. Install the lower intake manifold gasket onto the cylinder head.

    Use the gasket locator pins in order to properly seat the lower intake manifold gasket on the cylinder head.

    Fig 1: Applying Adhesive to Cylinder Head Side of Lower Intake Manifold Gasket
    G01977429Courtesy of GENERAL MOTORS CORP.
    NOTE: Apply the proper amount of the sealant when assembling this component. Excessive use of the sealant can prohibit the component from sealing properly. A component that is not sealed properly can leak leading to extensive engine damage.

    Important:  The lower intake manifold must be installed and the fasteners tightened while the adhesive is still wet to the touch.

  3. Apply a 5 mm (0.197 in) bead of adhesive GM P/N 12346141 (Canadian P/N 10953433) or equivalent to the front top of the engine block.
  4. Extend the adhesive bead 13 mm (0.50 in) onto each lower intake manifold gasket.
    Fig 2: Identifying Proper Application of Adhesive to Front Top of Engine Block
    G01977430Courtesy of GENERAL MOTORS CORP.
  5. Apply a 5 mm (0.197 in) bead of adhesive GM P/N 12346141 (Canadian P/N 10953433) or equivalent to the rear top of the engine block.
  6. Extend the adhesive bead 13 mm (0.50 in) onto each lower intake manifold gasket.
    Fig 3: Identifying Proper Application of Adhesive to Rear Top of Engine Block
    G01977431Courtesy of GENERAL MOTORS CORP.
  7. Install the lower intake manifold onto the engine block.
  8. If reusing the fasteners, apply threadlock GM P/N 12345382 (Canadian P/N 10953433) or equivalent to the threads of the lower intake manifold bolts.
  9. Install the lower intake manifold bolts.
    Fig 4: Installing Lower Intake Manifold
    G01977432Courtesy of GENERAL MOTORS CORP.
    NOTE: Proper lower intake manifold fastener tightening sequence and torque is critical. Always follow the tightening sequence, and torque the intake manifold bolts using the 3 step method. Failing to do so may distort the crankshaft bearing bore alignment and cause damage to the crankshaft bearings.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  10. Tighten the lower intake manifold bolts.

    Tighten 

    1. 10.1. Tighten the bolts on the first pass in sequence to 3 N.m (27 lb in).
    2. 10.2. Tighten the bolts on the second pass in sequence to 12 N.m (106 lb in).
    3. 10.3. Tighten the bolts on the final pass in sequence to 15 N.m (11 lb ft).
      Fig 5: Lower Intake Manifold Bolts Tightening Sequence
      G01977433Courtesy of GENERAL MOTORS CORP.
  11. Position the power steering pump mounting bracket.
  12. Loosely install the power steering pump mounting bracket bolts and nuts.
  13. Install the nut for the power steering pump rear bracket at the front of the engine.

    Tighten 

    Tighten the power steering pump mounting bracket bolts and the power steering pump rear bracket nuts to 41 N.m (30 lb ft).

  14. Install the drive belt. Refer to Drive Belt Replacement   .
  15. Install the fuel supply and return pipes to the rear of the intake manifold.
    Fig 6: View of Power Steering Pump
    G01977434Courtesy of GENERAL MOTORS CORP.

    Important:  In order to install the distributor for the correct engine timing, position the engine to number one cylinder top dead center.

  16. Remove the spark plug for number one cylinder.
  17. Rotate the crankshaft until number one cylinder is in the compression stroke.
  18. Align the 2 reference marks on the crankshaft balancer (1) and (4) with the 2 alignment marks (2) and (3) on the front cover.
  19. Install the spark plug. Refer to SPARK PLUGS in Service and Adjustment Specification - 4.3L in Engine Performance.
  20. Install the distributor. Refer to DISTRIBUTOR in Removal and Installation in Engine Performance.
  21. Install the EVAP canister purge solenoid valve. Refer to EVAP CANISTER in Removal and Installation in Engine Performance.
    Fig 7: Identifying Reference Marks on Crankshaft Balancer and Front Cover
    G01977435Courtesy of GENERAL MOTORS CORP.
  22. Install the PCV hose assembly to the intake manifold and the valve rocker arm cover.
    Fig 8: View of PCV Hose
    G01977436Courtesy of GENERAL MOTORS CORP.
  23. Install the accelerator cable and cruise control cable bracket to the throttle body.

    Tighten 

    Tighten the accelerator cable and cruise control bracket nuts to 9 N.m (80 lb in).

    Fig 9: Installing Accelerator Cable and Cruise Control Bracket
    G01977437Courtesy of GENERAL MOTORS CORP.
  24. Install the accelerator cable bracket to the intake manifold and the throttle body.

    Tighten 

    Tighten the accelerator cable bracket studs and nuts to 12 N.m (106 lb in).

    Fig 10: Installing Accelerator Cable Bracket Studs
    G01977438Courtesy of GENERAL MOTORS CORP.
  25. Position the engine wiring harness.
  26. Install the engine wiring harness clips in the brackets
  27. Connect the following electrical connectors:
    • The idle air control (IAC) motor (3)
    • The throttle position (TP) sensor (2)
    • The A/C compressor cutoff switch, if equipped (5)
    • The A/C clutch switch, if equipped (1)
    • The engine coolant temperature (ECT) sensor (4)
      Fig 11: Connecting Electrical Connectors
      G01977439Courtesy of GENERAL MOTORS CORP.
  28. Connect the following electrical connectors:
    • The fuel meter body assembly (1)
    • The EVAP canister purge solenoid valve (2)
    • The manifold air pressure (MAP) sensor (3)
      Fig 12: Connecting Electrical Connectors
      G01977440Courtesy of GENERAL MOTORS CORP.
  29. Connect the following electrical connectors:
    • The ignition coil (2)
    • The ignition control module (ICM) (1)
    • The generator (4)
      Fig 13: Connecting Electrical Connectors
      G01977441Courtesy of GENERAL MOTORS CORP.
  30. Connect the power brake booster vacuum hose.
  31. Connect the vacuum hose to the intake manifold, if equipped with A/C.
    Fig 14: View of Power Brake Booster Vacuum Hose
    G01977442Courtesy of GENERAL MOTORS CORP.
  32. Install the water pump inlet hose to the intake manifold.
  33. Install the heater hose to the intake manifold. Refer to HEATER HOSE REPLACEMENT - INLET (4.3L) and HEATER HOSE REPLACEMENT - OUTLET (4.3L) in Heating, Ventilation and Air Conditioning.
  34. Install the radiator inlet hose to the thermostat housing. Refer to RADIATOR HOSE REPLACEMENT - INLET (4.3L) in Engine Cooling.
  35. Install the cruise control cable, if equipped to the bracket and the throttle shaft. Refer to CRUISE CONTROL CABLE REPLACEMENT (4.3L) in Cruise Control.
    Fig 15: View of Water Pump Inlet Hose
    G01977443Courtesy of GENERAL MOTORS CORP.
  36. Install the accelerator cable onto the throttle body.
    Fig 16: Installing Accelerator Cable
    G01977444Courtesy of GENERAL MOTORS CORP.
  37. Wrap the cable in between the finger of the hook tab and the pulley wall. Make sure that the cable is fully seated in the pulley groove. The cable must not lie outside of the hook tab.
    Fig 17: Seating Cable in Pulley Groove
    G01977445Courtesy of GENERAL MOTORS CORP.
  38. Install the accelerator cable to the accelerator cable control bracket.
    Fig 18: Installing Accelerator Cable to Control Bracket
    G01977446Courtesy of GENERAL MOTORS CORP.
  39. Install the air cleaner outlet duct.
    Fig 19: View of MAF Sensor
    G01977447Courtesy of GENERAL MOTORS CORP.
  40. Connect the breather tube to the air cleaner outlet duct.
  41. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
  42. Connect the battery negative cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Battery.
    Fig 20: Connecting Breather Tube to Air Cleaner Outlet Duct
    G01977448Courtesy of GENERAL MOTORS CORP.
scientia non olet · About LEMON Manuals