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Home >> Chevrolet >> 2001 >> Venture Base, Van Passenger >> Repair and Diagnosis >> External Pages >> Different car >> Section 709 (Engine Mechanical - 3.8L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Intake Manifold Replacement - Upper >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2003 Pontiac Grand Prix. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Battery.
  2. Remove the fuel injector sight shield. Refer to FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L36)  or FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L67)  .
  3. Remove the air cleaner intake duct. Refer to AIR CLEANER INTAKE DUCT REPLACEMENT in Engine Performance - Removal and Installation.
  4. Drain the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
  5. Remove the right spark plug wires from the ignition control module and reposition. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION - V6 & V8 in Engine Performance - Removal and Installation.
    Fig 1: Removing Fuel Injector Sight Shield (Upper)
    G02083528Courtesy of GENERAL MOTORS CORP.
  6. Relieve the fuel pressure. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION - V6 & V8 in Engine Performance - Removal and Installation.
  7. Remove the fuel rail assembly. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION - V6 & V8 or ENGINE CONTROLS - REMOVAL & INSTALLATION - V6 & V8 in Engine Performance - Removal and Installation.
  8. Remove the brake booster hose from the vacuum source manifold.
  9. Remove the exhaust gas recirculation (EGR) valve wiring harness heat shield nut, bolt and the EGR heat shield.
  10. Remove the throttle body support bracket upper bolt.
  11. Disconnect the electrical connectors from the following:
    • EVAP purge solenoid
    • Throttle position (T/P) sensor
    • Idle air control (IAC) valve
    • Manifold absolute pressure (MAP) sensor
    • Mass air flow (MAF) sensor
  12. Remove the EVAP purge solenoid vacuum line from the throttle body.
  13. Remove the accelerator and the cruise control cables with the bracket from the throttle body. Refer to ACCELERATOR CONTROLS CABLE BRACKET REPLACEMENT in Engine Performance - Removal and Installation.
    Fig 2: Removing Throttle Body Support Bracket
    G02083529Courtesy of GENERAL MOTORS CORP.
  14. Remove the upper intake manifold bolts and stud.
  15. Clean the upper intake manifold bolt threads.
  16. Remove the upper intake manifold by lifting the back of the intake and sliding the manifold forward from the throttle body support bracket.
    Fig 3: Removing Upper Intake Manifold
    G02083530Courtesy of GENERAL MOTORS CORP.
  17. Remove the upper-to-lower intake manifold carrier gasket from the upper intake manifold.
  18. If the upper intake manifold is being replaced, remove the following:
    • Throttle body
    • Manifold absolute pressure (MAP) sensor
    • Positive crankcase ventilation (PCV) valve
    • Vacuum source manifold
    Fig 4: Removing Gasket From Upper Intake Manifold
    G02083531Courtesy of GENERAL MOTORS CORP.
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