LEMON Manuals: Even more car manuals for everyone
Home >> Chevrolet >> 2001 >> Camaro Base, 2D Convertible, Automatic >> Repair and Diagnosis >> External Pages >> Different car >> Section 63 (Engine Mechanical - 3.8L (On-Vehicle)) >> Repair Instructions >> Intake Manifold Replacement - Upper >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2002 Pontiac Firebird and 2002 Chevrolet Camaro. However, it is still accessible from the selected car via links, so may be relevant.
  1. Drain the engine coolant. Refer to DRAINING AND FILLING COOLING SYSTEM .
  2. Disconnect the intake air temperature (IAT) sensor electrical connector.
    Fig 1: Disconnecting Intake Air Temperature (IAT) Sensor
    G01728715Courtesy of GENERAL MOTORS CORP.
  3. Remove the air intake duct.
    Fig 2: Removing Air Intake Duct
    G01728716Courtesy of GENERAL MOTORS CORP.
  4. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
  5. Disconnect the right side fuel injector electrical connectors (1) from the fuel injectors.
    Fig 3: Disconnecting Right Side Fuel Injector Electrical Connectors
    G01728717Courtesy of GENERAL MOTORS CORP.
  6. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (2).
  7. Remove the engine harness vacuum tube (1) from the vacuum port.
    Fig 4: Removing Engine Harness Vacuum Tube
    G01728718Courtesy of GENERAL MOTORS CORP.
  8. Remove the fuel pressure regulator tube (2) from the following components:
    • Manifold vacuum source (1)
    • Fuel pressure regulator valve (3)
    Fig 5: Removing Fuel Pressure Regulator Tube
    G01728719Courtesy of GENERAL MOTORS CORP.
  9. Disconnect the left side fuel injector electrical connectors (1) from the fuel injectors.
    Fig 6: Disconnecting Left Side Fuel Injector Electrical Connectors
    G01728720Courtesy of GENERAL MOTORS CORP.
  10. Disconnect the evaporative emission (EVAP) canister purge valve switch electrical connector (2).
  11. Relieve the fuel pressure. Refer to FUEL SYSTEM PRESSURE RELEASE .
  12. Disconnect the fuel lines from the fuel rail. Refer to REMOVAL (QUICK-CONNECT FITTING - WITH METAL .
  13. Disconnect the fuel vapor line from the EVAP canister purge valve. Refer to REMOVAL (QUICK-CONNECT FITTING - WITH PLASTIC) .
  14. Remove the ignition control module. Refer to IGNITION CONTROL MODULE .
  15. Reposition the brake booster hose clamp.
  16. Remove the brake booster hose (2) from the upper intake manifold fitting (1).
    Fig 7: Removing Brake Booster Hose
    G01728721Courtesy of GENERAL MOTORS CORP.
  17. Disconnect the electronic throttle control (ETC) electrical connector (1).
    Fig 8: Disconnecting Electronic Throttle Control (ETC) Electrical Connector
    G01728722Courtesy of GENERAL MOTORS CORP.
  18. Disconnect the following electrical connectors:
    • Mass airflow (MAF) sensor (1)
      Fig 9: Disconnecting Mass Airflow (MAF) Sensor
      G01728723Courtesy of GENERAL MOTORS CORP.
    • Engine coolant temperature (ECT) sensor (2)
  19. Remove the engine harness clip (3) from the throttle body.
  20. Remove the engine harness clamp bolt (5) and harness clamp (4).
  21. Reposition the engine wiring harness.
  22. Remove the thermostat housing. Refer to THERMOSTAT HOUSING REPLACEMENT (3.8L ENGINE) .
  23. Remove the wiring harness clips from the fuel rail.
  24. Reposition the wiring harness.
  25. Remove the fuel rail nuts (1).
    Fig 10: Removing Fuel Rail Nuts
    G01728724Courtesy of GENERAL MOTORS CORP.

    Important:  Clean any dirt out of the injector bores with compressed air.

  26. Remove the fuel rail (2) from the upper intake manifold.
  27. Remove the upper intake manifold bolts (1, 3, 4).
    Fig 11: Removing Upper Intake Manifold Bolts
    G01728725Courtesy of GENERAL MOTORS CORP.
  28. Remove the upper intake manifold (2).
  29. Remove the upper intake manifold gasket (1).
  30. Clean the upper and lower intake manifold mating surfaces.
    Fig 12: Cleaning Upper And Lower Intake Manifold Mating Surfaces
    G01728726Courtesy of GENERAL MOTORS CORP.
  31. If replacing the manifold remove the manifold vacuum source screws (2) and manifold vacuum source (1).
    Fig 13: Removing Manifold Vacuum Source Screws And Manifold Vacuum Source
    G01728727Courtesy of GENERAL MOTORS CORP.
  32. If replacing the manifold remove the EVAP purge valve bolts (1) and purge valve (2).
    Fig 14: Removing EVAP Purge Valve Bolts
    G01728728Courtesy of GENERAL MOTORS CORP.
  33. If replacing the manifold bolt (1), nuts (2), throttle body (3) and gasket (4).
    Fig 15: Remove Throttle Body
    G01728729Courtesy of GENERAL MOTORS CORP.
  34. Remove lower intake manifold O-rings seals (3, 4), if necessary.
    Fig 16: Removing Lower Intake Manifold O-Rings Seals
    G01728730Courtesy of GENERAL MOTORS CORP.
scientia non olet · About LEMON Manuals