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Home >> Chevrolet >> 2001 >> Venture Base, Van Passenger >> Repair and Diagnosis >> External Pages >> Different car >> Section 165 (Engine Mechanical - 4.0L (On-Vehicle)) >> Repair Instructions >> Intake Manifold Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2002 Oldsmobile Aurora. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the 2 nuts (2) from the intake manifold sight shield (1).
  2. Remove the sight shield (1) from the engine.
    Fig 1: Removing Fuel Injector Sight Shield
    G01819237Courtesy of GENERAL MOTORS CORP.
  3. Disconnect the coil module connectors (1) from the coil modules (2) located in the camshaft covers (3).
    Fig 2: Disconnecting Coil Module Connectors
    G01819238Courtesy of GENERAL MOTORS CORP.
  4. Disconnect the PCV dirty air tube (2) from the camshaft cover.
    Fig 3: Disconnecting PCV Dirty Air Tube
    G01819239Courtesy of GENERAL MOTORS CORP.
  5. Disconnect the PCV fresh air tube (1) from the camshaft cover.
    Fig 4: Disconnecting PCV Fresh Air Tube
    G01819240Courtesy of GENERAL MOTORS CORP.
  6. Disconnect the fuel regulator vacuum tube (1).
  7. Disconnect the vacuum tubes (2) from the AIR solenoid.
    Fig 5: Disconnecting Vacuum Tubes
    G01819241Courtesy of GENERAL MOTORS CORP.
  8. Disconnect the fuel inlet and return quick-connect fittings (2) at the fuel rail.
  9. Disconnect the fuel rail bracket retaining nut (1) at the rear lift bracket.
    Fig 6: Disconnecting Fuel Inlet & Return Fittings & Fuel Rail Bracket Nut
    G01819242Courtesy of GENERAL MOTORS CORP.
  10. Remove the 2 pushnuts securing the engine coolant heater wire (1) and position aside (if equipped).
  11. Carefully position aside the surge tank pipe (2) from the fuel rail studs.
    Fig 7: Removing Engine Coolant Heater Wire Pushnuts
    G01819243Courtesy of GENERAL MOTORS CORP.
  12. Disconnect the 8 electrical connectors (1) from the 8 fuel injectors (2).
    Fig 8: Disconnecting Fuel Injector Electrical Connectors
    G01819244Courtesy of GENERAL MOTORS CORP.
  13. Remove the 4 bolts (1) attaching the fuel rail (2) to the intake manifold (3).
    Fig 9: Removing Fuel Rail Bolts
    G01819245Courtesy of GENERAL MOTORS CORP.
  14. Lift the entire fuel rail and injector assembly from the intake manifold.
    Fig 10: Removing Fuel Rail & Injector Assembly
    G01819246Courtesy of GENERAL MOTORS CORP.
  15. Loosen the plenum duct clamp (1) at the rear of the intake manifold.
    Fig 11: Identifying Plenum Duct Clamp
    G01819247Courtesy of GENERAL MOTORS CORP.
  16. Remove ten bolts attaching the intake manifold (1) to the cylinder heads.
    Fig 12: Removing Intake Manifold Bolts
    G01819248Courtesy of GENERAL MOTORS CORP.
  17. Remove the intake manifold (1) by using an upward lifting motion at the front of the manifold assembly.
  18. Clean and inspect the intake manifold. Refer to INTAKE MANIFOLD CLEANING AND INSPECTION .
    Fig 13: Removing Intake Manifold
    G01819249Courtesy of GENERAL MOTORS CORP.
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