OEM 2002 Chevrolet Camaro Intake Manifold

2002 Chevrolet Camaro Parts Questions & Experts Answers

• Q: How to replace the upper intake manifold on 2002 Chevrolet Camaro?

  A: Start the upper Intake Manifold replacement process by draining the engine coolant followed by disconnecting the intake air temperature (IAT) sensor electrical connector. The right side fuel injector electrical connectors need to be removed from their fuel injectors followed by unplugging the manifold absolute pressure (MAP) sensor electrical connector . The engine harness vacuum tube must be removed from its vacuum port position and the fuel pressure regulator tube from its manifold vacuum source and fuel pressure regulator valve. Electrically disconnect the left side fuel injector connectors and the evaporative emission (EVAP) canister purge valve switch connector . The first step involves lowering fuel pressure and removing the fuel lines from the rail and disconnecting the evap canister purge valve fuel vapor connection. To remove the Ignition Control Module you should clamp down the brake booster hose while you disconnect the brake booster hose from its upper Intake Manifold fitting. Remove power from electronic throttle control (ETC) components by disconnecting its electrical connector with the mass airflow (MAF) sensor and engine coolant temperature (ECT) sensor electrical connectors. After removing the engine harness clip from the Throttle Body you should also detach the engine harness clamp bolt and harness clamp before repositioning the engine wiring harness. First remove the Fuel Rail wires with clips attached to the Thermostat Housing then place the harness at its forward position. Use compressed air to clear dirt from injector bores before losing the Fuel Rail nuts and removing the Fuel Rail from the upper Intake Manifold. Unbolt the upper Intake Manifold at points 1, 3, and 4 while simultaneously removing the upper Intake Manifold with its gasket. Prior to assembly test the manifold vacuum source for leaks then remove it with screws. Next remove the evap valve bolts and its purge valve. Also disassemble the Throttle Body by removing its bolt and nuts and gasket and body. Begin installation by putting new o-ring seals (3, 4) on the lower Intake Manifold if they were removed before installing the upper Intake Manifold gasket for placement on the lower Intake Manifold. Secure the upper Intake Manifold bolts (1, 3, 4) in a specific sequence while torquing the 9 upper Intake Manifold bolts to 15 nm (11 ft. Lbs.), the 2 upper Intake Manifold bolts to 30 nm (22 ft. Lbs.) and the upper Intake Manifold bolt to 15 nm (11 ft. Lbs.). For upper Intake Manifold replacement, start by installing the Throttle Body Gasket and Throttle Body. Next install Throttle Body bolt and nuts. Tighten the Throttle Body nuts to 10 nm (89 inch lbs.) and the Throttle Body bolt to 10 nm (89 inch lbs.). Position the Fuel Rail onto the upper Intake Manifold while tightening its nuts to 9 nm (80 inch lbs.). Secure wiring harness clips across three main components including the Fuel Rail and Thermostat Housing before repositioning the engine harness. Position the engine harness clamp at the correct location then apply 6 nm torque (53 inch lbs.) to the harness clamp bolt . Continue with engine harness clip installation on the Throttle Body. Establish connections between electrical sensors of maf sensor and ect sensor then proceed to etc electrical connector installation. Fasten the brake booster hose to the upper Intake Manifold fitting then place the brake booster hose clamp in position. First install the Ignition Control Module after installing the evap canister purge valve onto the upper Intake Manifold using 10 nm (89 inch lbs.) torque. Attach the fuel vapor line to the evap canister purge valve and connect the fuel lines to the Fuel Rail followed by plugging in electrical connectors for both the evap canister purge valve and left-side fuel injectors. Place the manifold vacuum source on the upper Intake Manifold with torques of 10 nm (89 inch lbs.) applied on the screws. Route the fuel pressure regulator tube through the manifold vacuum source and fuel pressure regulator valve segment while connecting the MAP Sensor electrical connector with the engine harness vacuum tube and the right side fuel injector electrical connectors to their proper destinations. Finish by installing the drive belt tensioner and air intake duct then connecting the iat sensor electrical connector followed by filling engine coolant.