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 - Upper >> Removal Procedure

Removal 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.

Important:  The upper intake does not have to be removed to remove the lower intake manifold.

  1. Disconnect the breather tube at the air cleaner outlet duct.
    Fig 1: Breather Tube And Air Cleaner Outlet Duct
    G01977376Courtesy of GENERAL MOTORS CORP.
  2. Remove the air cleaner outlet duct retaining wingnut.
    Fig 2: Identifying Air Cleaner Outlet Duct Retaining Wingnut
    G01977377Courtesy of GENERAL MOTORS CORP.
  3. Disconnect the IAT sensor harness connector.
    Fig 3: Identifying IAT Sensor Harness Connector
    G01977378Courtesy of GENERAL MOTORS CORP.
  4. Remove the air cleaner outlet duct from the throttle body.
    Fig 4: View of Air Cleaner Outlet Duct
    G01977379Courtesy of GENERAL MOTORS CORP.
  5. Disconnect the accelerator cable from the throttle body.
    Fig 5: Accelerator Cable And Throttle Body
    G01977380Courtesy of GENERAL MOTORS CORP.
  6. Remove the accelerator cable from the accelerator control cable bracket.
    Fig 6: Accelerator Cable And Accelerator Control Cable Bracket
    G01977381Courtesy of GENERAL MOTORS CORP.
  7. Disconnect the cruise control cable, if equipped from the throttle shaft and the accelerator cable bracket. Refer to CRUISE CONTROL CABLE REPLACEMENT (4.3L) in Cruise Control.
  8. Disconnect the vacuum hose from the intake manifold for the vacuum tank.
  9. Remove the power brake booster vacuum hose.
    Fig 7: View of Power Brake Booster Vacuum Hose
    G01977382Courtesy of GENERAL MOTORS CORP.
  10. Disconnect the following electrical connectors:
    • The A/C compressor clutch (1)
    • The A/C compressor cutoff switch (5), if equipped
    • The throttle position (TP) sensor (2)
    • The idle air control (IAC) motor (3)
      Fig 8: Electrical Connectors
      G01977383Courtesy of GENERAL MOTORS CORP.
  11. Disconnect the following electrical connectors:
    • The fuel meter body assembly (1)
    • The manifold absolute pressure (MAP) sensor (3)
    • The EVAP canister purge solenoid valve (2)
  12. Remove the engine wire harness clip from the accelerator cable bracket.
  13. Move the engine wiring harness aside.
    Fig 9: Electrical Connectors
    G01977384Courtesy of GENERAL MOTORS CORP.
  14. Remove the accelerator cable bracket from the throttle body and the intake manifold.
    Fig 10: View of Accelerator Cable Bracket
    G01977385Courtesy of GENERAL MOTORS CORP.
  15. Remove the accelerator and cruise control cable bracket from the throttle body.

    Leave the accelerator and cruise control cables on the bracket.

    Fig 11: Accelerator And Cruise Control Cable Bracket
    G01977386Courtesy of GENERAL MOTORS CORP.
  16. Remove the PCV valve hose assembly from the intake manifold and the valve rocker arm cover.
    Fig 12: View of PCV Valve Hose
    G01977387Courtesy of GENERAL MOTORS CORP.
  17. Remove the bracket for the engine wiring harness from the intake manifold stud.
  18. Remove the fuel lines from the fuel meter body assembly.
  19. Remove the EVAP canister purge solenoid valve. Refer to EVAP CANISTER in Removal and Installation in Engine Performance.
    Fig 13: View of Engine Wiring Harness Bracket
    G01977388Courtesy of GENERAL MOTORS CORP.
  20. Remove the studs for the upper intake manifold.
  21. Remove the upper intake manifold.
    Fig 14: Upper Intake Manifold
    G01977389Courtesy of GENERAL MOTORS CORP.
  22. Remove the upper intake manifold gasket from the groove.
  23. Discard the gasket.
    Fig 15: Upper Intake Manifold Gasket
    G01977390Courtesy of GENERAL MOTORS CORP.
  24. Remove the seal from the fuel meter body assembly.
  25. Discard the seal

    Important:  Do not immerse the assembled upper intake manifold in cleaning solvent.

  26. Clean all sealing surfaces and the inside of the upper intake manifold with a shop towel and cleaning solvent.
  27. Inspect the upper intake manifold for the following:
    • Cracks or other damage to the exterior
    • Cracking or damage to the gasket grooves
    • Loose or damaged bolt hole thread inserts
    • Damage to the throttle body mounting surface
      Fig 16: Fuel Meter Body Seal
      G01977391Courtesy of GENERAL MOTORS CORP.
  28. If replacing the upper intake manifold, turn and remove the power brake booster vacuum tube fitting from the upper intake manifold.
  29. Remove and discard the seal.
    Fig 17: Power Brake Booster Vacuum Tube
    G01977392Courtesy of GENERAL MOTORS CORP.
  30. If replacing the upper intake manifold, turn and remove the PCV valve cover from the upper intake manifold.
  31. Remove and discard the seal.
  32. Remove the throttle body if replacing the upper intake manifold. Refer to THROTTLE BODY in Removal and Installation in Engine Performance.
  33. Remove the MAP sensor if replacing the upper intake manifold. Refer to MANIFOLD ABSOLUTE PRESSURE SENSOR in Removal and Installation in Engine Performance.
    Fig 18: PCV Valve Cover
    G01977393Courtesy of GENERAL MOTORS CORP.
scientia non olet · About LEMON Manuals