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Home >> Chevrolet >> 2001 >> Venture Base, Van Passenger >> Repair and Diagnosis >> External Pages >> Different car >> Section 390 (Engine Mechanical - 3.8L (On-Vehicle)) >> Repair Instructions >> Intake Manifold Replacement - Lower (L67) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2002 Buick Regal. However, it is still accessible from the selected car via links, so may be relevant.
  1. Drain the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in ENGINE COOLING .
  2. Remove the supercharger. Refer to Supercharger Replacement 
  3. Remove the radiator inlet hose from the water outlet housing. Refer to or RADIATOR HOSE REPLACEMENT - INLET (3.8L) in ENGINE COOLING .
    Fig 1: Radiator Inlet Hose From The Water Outlet Housing
    G01764159Courtesy of GENERAL MOTORS CORP.
  4. Remove the EGR outlet pipe from the lower intake manifold.
  5. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
    Fig 2: ECT Sensor Electrical Connector
    G01764160Courtesy of GENERAL MOTORS CORP.
  6. Remove the lower intake manifold bolts.
  7. Remove the lower intake manifold. The coolant bypass tube will release from the intake manifold as the manifold is removed.
  8. Remove the lower intake manifold seals.
  9. Remove the lower intake manifold gaskets.
    Fig 3: Lower Intake Manifold And Seals
    G01764161Courtesy of GENERAL MOTORS CORP.
  10. If replacing the lower intake manifold, remove the water outlet housing bolt and stud, the water outlet housing, the gasket and the thermostat.
  11. If replacing the lower intake manifold, remove the engine coolant temperature (ECT) sensor.
  12. Inspect the flatness of the inlet flanges.
  13. Clean the lower intake manifold mating surfaces.
  14. Clean the intake manifold bolts and bolt holes of the adhesive compound.
    Fig 4: Thermostat
    G01764162Courtesy of GENERAL MOTORS CORP.
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