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Home >> Chevrolet >> 2001 >> Venture Base, Van Passenger >> Repair and Diagnosis >> External Pages >> Different car >> Section 752 (Engine Mechanical) >> Repair Instructions >> On-Vehicle Repair Instructions >> Intake Manifold Replacement - Lower >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2003 Pontiac Montana, 2003 Oldsmobile Silhouette, and 2003 Chevrolet Venture. However, it is still accessible from the selected car via links, so may be relevant.

Important:  The fuel injector wiring harness connectors must be connected to their respective fuel injectors. Failure to connect the fuel injector connectors to their respective fuel injectors may result in excessive exhaust emissions and poor engine performance.

  1. Remove the upper intake manifold. Refer to INTAKE MANIFOLD REPLACEMENT - UPPER   . 
  2. Remove the engine left side valve rocker arm cover. Refer to VALVE ROCKER ARM COVER REPLACEMENT - LEFT   . 
  3. Remove the engine right side valve rocker arm cover. Refer to VALVE ROCKER ARM COVER REPLACEMENT - RIGHT   . 
  4. Disconnect the wiring harness from the engine coolant temperature (ECT) sensor.

    Important:  Use masking tape or another appropriate method in order to identify each fuel injector wiring harness connector cylinder number.

  5. Disconnect and remove the fuel injector, manifold air pressure (MAP) and ECT wiring harness.
  6. Remove the fuel feed and return pipe from the fuel injector rail. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION & OVERHAUL  in Removal and Installation in Engine Performance.
    Fig 1: Disconnecting Wiring Harness From Engine Coolant Temperature (ECT) Sensor
    G01485394Courtesy of GENERAL MOTORS CORP.
    Fig 2: Disconnecting And Removing Fuel Injector, Manifold Air Pressure (MAP) And ECT Wiring Harness
    G01485395Courtesy of GENERAL MOTORS CORP.
  7. Remove the fuel injector rail. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION & OVERHAUL  in Removal and Installation in Engine Performance.

    Important:  Do NOT disconnect the power steering pipes or hoses from the power steering pump.

  8. Remove the power steering pump from the front engine cover and reposition aside. Refer to Power POWER STEERING PUMP REPLACEMENT  in Power Steering System.
  9. Disconnect the heater inlet pipe with heater hose from the lower intake manifold and reposition aside. Refer to HEATING, VENTILATION AND AIR CONDITIONING  in Heating, Ventilation and Air Conditioning.
  10. Disconnect the inlet radiator hose from the engine. Refer to RADIATOR HOSE REPLACEMENT - INLET  in Engine Cooling.
    Fig 3: Removing Fuel Injector Rail
    G01485396Courtesy of GENERAL MOTORS CORP.
  11. Disconnect the thermostat bypass hose from the lower intake manifold pipe.
    Fig 4: Disconnecting Thermostat Bypass Hose From Lower Intake Manifold Pipe
    G01485397Courtesy of GENERAL MOTORS CORP.
  12. Remove the lower intake manifold bolts.
    Fig 5: Removing Lower Intake Manifold Bolts
    G01485398Courtesy of GENERAL MOTORS CORP.
  13. Remove the lower intake manifold.
  14. Loosen the valve rocker arms and remove the push rods.
    Fig 6: Removing Lower Intake Manifold
    G01485399Courtesy of GENERAL MOTORS CORP.
  15. Remove the lower intake manifold gaskets and seals.
  16. Clean the lower intake manifold gasket and seal surfaces on the cylinder heads and the engine block.
  17. Clean and inspect the lower intake manifold.
  18. If you are replacing the lower intake manifold, remove the ECT sensor. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION & OVERHAUL  in Removal and Installation in Engine Performance.
  19. If you are REPLACING the lower intake manifold, remove the thermostat. Refer to THERMOSTAT REPLACEMENT  in Engine Cooling.
    Fig 7: Removing Lower Intake Manifold Gaskets And Seals
    G01485400Courtesy of GENERAL MOTORS CORP.
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