OEM 2002 GMC Safari Intake Manifold

2002 GMC Safari Parts Questions & Experts Answers

• Q: How to replace the lower intake manifold on 2002 GMC Safari?

  A: To change the lower Intake Manifold, first you should disconnect the negative cable from the battery and remove the engine cover. Drain the cooling system and remove the air cleaner assembly and air cleaner outlet duct from the Throttle Body assembly. Remove the accelerator control cable from the throttle shaft and bracket, and if so equipped disconnect the cruise control cable from the throttle shaft and bracket. Remove the PCV Valve Hose assembly from the Intake Manifold and valve rocker arm cover, detach the nut that secures an a/c hose bracket, and the nut for the engine wiring harness to the Intake Manifold stud. Disconnect the electrical connectors for the a/c compressor clutch, a/c high pressure cutoff switch, throttle position (TP) sensor, idle air control (IAC) motor, fuel meter body assembly connector, manifold absolute pressure (MAP) sensor, evap canister purging solenoid valve. Remove the ground wire from the water outlet stud, the nut and engine wiring harness bracket from the evap canister purge solenoid valve stud and secure the engine wire harness out of the way. Your work surface should include unbending the radiator inlet hose, heater hose, and water pump inlet hose from the Intake Manifold, as well as the vacuum hose. Mount the new bolt to the bottom of the filler tube. Drive out the old bolt on the bottom of the a/c compressor and remove it from the compressor together with the bracket.grp screw in the lower clamp that secures the rubber hose to the vehicle frame damn to the ram air box and then the box to the frame.mount the new bolt to the bottom of the filler tube and then remove with a socket the filler tube and the Throttle Body and the Intake Manifold. Take out the Distributor and disconnect the fuel return and supply pipes near the manifold at the rear. To gain access to the front Intake Manifold bolt remove the Drive Belt, a/c compressor side brace, loosen the power steering pump rear bracket nut, and oil filler tube bracket bolt and remove the oil filler tube. Loose the bolts and nut for the power steering pump bracket mounting bracket, leaving the a/c compressor and power steering pump at the bracket, and slide the power steering pump bracket forward to access the front Intake Manifold bolt. When taken off the lower Intake Manifold clean all sealing surface. For installation, position the lower Intake Manifold and reinstall power steering pump mounting bracket. Fix the 3 bolts and nut for the mounting bracket of the power steering pump and tighten it on to 41 nm (30 ft. Lbs.), then for the side brace side of the a/c compressor and bolt tighten to 50 nm (37 ft. Lbs,) the brace bolt 50 nm (37 ft. Lbs) followed by the other bolt to 25 nm (18 ft. Lbs). Install the oil filler tube and bolt and tighten to 25 nm (18 ft. Lbs.), the Drive Belt, evap canister purge valve, and fuel supply and return pipes. For proper engine timing connect the engine at number one cylinder top dead center point, and remove the Spark Plug for number one cylinder on the engine, rotate and bring the Crankshaft into the compression stroke, then align the reference marks on the Crankshaft balancer (1, 4) with marks on the Distributor front cover (2, 3) and then reattach the Spark Plug and Distributor. Mount the ignition control module (ICM), accelerator control cable bracket, studs, and nuts to the Intake Manifold and Throttle Body and tighten them to 12 nm (106 inch lbs.). Reconnect the vacuum hose, transmission fluid fill tube, and bolt to the accelerator control cable bracket with 6 nm (53 inch lbs.) and and install the water pump inlet hose, heater hoses, and radiator inlet hose. Replace the engine wires harness and connect the electrical connectors from the a/c compressor clutch , a/c high pressure cutoff switch , throttle position (TP) , idle air control (IAC) motor , fuel meter body assembly connector , map sensor , and evap canister purge solenoid valve. Install the ground wire and nut to the water outlet stud to 19 nm (14 ft. Lbs.), the nut and engine wiring harness bracket to the evap canister purge valve stud (8 Nm 7 or lbs.) and the Intake Manifold stud (12 Nm or 106 inch lbs.). If provisioned, apply gelix to the nut and install onto the Intake Manifold stud with 5 nm (44 inch lbs.) and then attach the PCV Valve Hose assembly to the Intake Manifold and valve rocker arm cover. Install the cruise control cable if is available, as well as the accelerator control cable. Refill the cooling system, join the air cleaner outlet duct to the Throttle Body, the air cleaner assembly, rejoin the battery negative cable, and finally, the cover on the engine.