Removal (Lower)

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2002 GMC Savana Special, 2002 GMC Savana Camper Special, 2002 GMC Savana, 2002 Chevrolet RV Cutaway, and 2002 Chevrolet Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

Disconnect the battery negative cable from the battery. Remove the interior engine cover from the vehicle (if equipped). Remove the air cleaner assembly from the vehicle. Remove the air intake duct from the turbocharger.
Remove the upper intake manifold bolts. See Figure. Remove the upper intake manifold. Remove the gaskets from the lower intake manifold. Remove the seal from the turbocharger.
NOTE: The lower intake comes in 2 sections. If replacing both the left side and the right side perform all of the following steps. If replacing only the left side perform steps 3- 6 and step 10. If replacing only the right side perform steps 6- 10 .
Remove the transmission oil level indicator tube upper section from the upper intake manifold. Remove the oil level indicator from the tube. Remove the nut retaining the oil level indicator to the thermostat crossover. Separate the upper section of the oil level indicator tube from the lower section.
If equipped with rear air conditioning (A/C), remove the rear A/C pipe from the A/C compressor. Remove the nuts retaining the rear A/C pipe brackets from the upper intake manifold (if equipped). Position the rear A/C pipe out of the way. Drain the engine coolant. See DRAINING & FILLING COOLING SYSTEM .
Remove the upper radiator hose. Disconnect the gray engine harness electrical connector. See Fig 1. Remove the electrical harness and retaining brackets from the upper intake manifold (if needed). See Fig 2. Remove the nuts retaining the fuel pipe brackets. Remove the bracket for retaining the CDR valve from the right side lower intake manifold studs.
Remove the CDR valve.

NOTE: The sensors and the solenoids attached to the lower intake manifold require removal in order to prevent damage when cleaning with solvent cleaning.

Disconnect the Intake Air Temperature (IAT) sensor electrical connector. Remove the IAT sensor. See Fig 3. Disconnect the Boost sensor electrical connector by releasing the locking tab. Remove the Boost sensor retaining bolts. See Fig 4. Remove the Boost sensor. Remove the gasket.
Disconnect the glow plug relay electrical connectors by releasing the locking tab. Remove the hold down nuts on the glow plug relay power supply terminals. See Fig 5. Remove the glow plug relay power supply terminals. Remove the glow plug relay retaining nuts. Remove the glow plug relay. See Fig 6.
Disconnect the wastegate solenoid wiring harness connector by releasing the locking tab/removing mounting bolt. See Fig 7. Remove the vacuum hose harness. Remove the wastegate solenoid retaining bolts. Remove the wastegate solenoid. Remove the wastegate solenoid mounting bracket retaining nuts. Remove the wastegate solenoid mounting bracket. Remove the electrical harness retaining clips. Position the engine wiring harness out of the way.
Remove the lower intake manifold bolts. See Fig 8. Remove the lower intake manifold and gaskets from the cylinder heads. Inspect and clean the sealing surfaces.