OEM 2002 Chevrolet Tahoe Intake Manifold

2002 Chevrolet Tahoe Parts Questions & Experts Answers

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

  A: To remove the Intake Manifold, first, one needs to remove the Throttle Body and fuel injectors from the manifold and disconnect the electrical connectors for the manifold absolute pressure (MAP) sensor, knock sensor, and exhaust gas recirculation (EGR) valve if equipped. Unplug the Knock Sensor harness connector and lay the electrical harness aside. If equipped, then take the EGR pipe bolts from the Intake Manifold, cylinder heads, and Exhaust Manifold and remove the EGR pipe with valve and gasket. In the case of vacuum-assisted brake vehicles, remove the vacuum brake booster hose from the back of the Intake Manifold. Then, remove the positive crankcase ventilation (PCV) hose with valve, the MAP Sensor, and the accelerator control cable bracket bolts prior to removing the bracket. Disengage the evaporative emission (EVAP) purge solenoid vent tube from the tube end on the solenoid, and the evap tube end from the vapor pipe, by squeezing the evap pipe quick connect fitting retainer. Unbolt the evap purge solenoid bolt, solenoid, and isolator from the Intake Manifold, and then unplug the manifold bolts, and manifold. Remove the Intake Manifold Gasket and discard the old ones, clean and check the Intake Manifold, and also make sure to clean the EGR pipe and Exhaust Manifold gasket surface if available. For installation, put the new Intake Manifold gaskets on the Intake Manifold, put the manifold on, then apply a 5mm (0.20 in) band of threadlock GM U.S. P/N 12345382, Canada P/N 10953489 or equivalent to the flange bolts of the Intake Manifold. Tighten the Intake Manifold bolts in sequence to 5 nm (44 inch lbs.) for the first pass and 10 nm (89 inch lbs.) for the final pass. Mount the evap purge solenoid, isolator, and bolt, securing the solenoid bolt to 10 nm (89 inch lbs.) to the Intake Manifold. Reconnect the solenoid and the vent tube to the solenoid vent line and pipe. Then install the accelerator control cable bracket and its bolts and tighten the bolts to 10 nm (89 inch lbs.). Lightly apply clean engine oil on the MAP Sensor seal, reinstalling the MAP Sensor to the Intake Manifold with the PCV hose with valve. If equipped, install a new EGR pipe gasket on the Exhaust Manifold and EGR pipe with valve, tighten the EGR pipe nuts to the Intake Manifold, cylinder head, and Exhaust Manifold as noted. 10 nm 89 inch lbs process the pipe-to-Intake Manifold bolts, 50 nm 37 ft. lbs process the pipe-to-cylinder head bolts, and 30 nm 22 ft. lbs process the pipe-to-exhaust manifold bolts. Position the electrical harness into place over the engine, connect the Knock Sensor harness to the Intake Manifold, reattach the MAP Sensor, knock sensor, and the EGR Valve if so. Lastly, mate the fuel injectors and Throttle Body.