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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 - Upper >> 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. Drain the engine coolant from the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM  in Engine Cooling.
  2. Remove the throttle body air inlet duct. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION & OVERHAUL  in Removal and Installation in Engine Performance.
  3. Remove the accelerator control and cruise control cables with bracket from the throttle body. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION & OVERHAUL  in Removal and Installation in Engine Performance.
  4. Disconnect the wiring harness connectors from the following throttle body components:
    • Throttle Position (TP) sensor
    • Idle Air Control (IAC) valve
  5. Disconnect the engine left side spark plug wires. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION & OVERHAUL  in Removal and Installation in Engine Performance.
  6. Disconnect the engine left side spark plug wire harness attachment clip. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION & OVERHAUL  in Removal and Installation in Engine Performance.
  7. Disconnect the throttle body heater hoses. Refer to THROTTLE BODY HEATER HOSE REPLACEMENT - INLET  and  THROTTLE BODY HEATER HOSE REPLACEMENT - OUTLET  in Engine Cooling.
  8. Disconnect the vacuum hoses from the evaporative emission (EVAP) canister purge solenoid valve.
  9. Remove the EVAP canister purge solenoid valve. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION & OVERHAUL  in Removal and Installation in Engine Performance.
    Fig 1: Identifying Intake Manifold
    G01485375Courtesy of GENERAL MOTORS CORP.
  10. Remove the ignition coil bracket.
    Fig 2: Removing Ignition Coil Bracket
    G01485376Courtesy of GENERAL MOTORS CORP.
  11. Disconnect the wiring harness from the manifold air pressure (MAP) sensor.
    Fig 3: Disconnecting Wiring Harness From Manifold Air Pressure (MAP) Sensor
    G01485377Courtesy of GENERAL MOTORS CORP.
  12. Disconnect the vacuum harness from the MAP sensor and the upper intake manifold.
    Fig 4: Disconnecting Vacuum Harness From MAP Sensor And Upper Intake Manifold
    G01485378Courtesy of GENERAL MOTORS CORP.
  13. Disconnect and remove the emission control vacuum harness.
  14. Disconnect the vacuum brake booster hose from the upper intake manifold. Refer to POWER BRAKE BOOSTER CHECK VALVE AND/OR HOSE REPLACEMENT  in Hydraulic Brakes.
  15. Disconnect the vacuum hose connections from the upper intake manifold.
    • Heating, ventilation and air conditioning (HVAC) vacuum source hose
    • Fuel pressure regulator
  16. Remove the exhaust gas recirculation (EGR) valve. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION & OVERHAUL  in Removal and Installation in Engine Performance.
  17. Remove the MAP sensor and the bracket. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION & OVERHAUL  in Removal and Installation in Engine Performance.
    Fig 5: Disconnecting And Removing Emission Control Vacuum Harness
    G01485379Courtesy of GENERAL MOTORS CORP.
  18. Remove the upper intake manifold studs and bolts.
    Fig 6: Removing Upper Intake Manifold Studs And Bolts
    G01485380Courtesy of GENERAL MOTORS CORP.
  19. Remove the upper intake manifold.
    Fig 7: Removing Upper Intake Manifold
    G01485381Courtesy of GENERAL MOTORS CORP.
  20. If you are REPLACING the intake manifold, remove the throttle body. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION & OVERHAUL  in Removal and Installation in Engine Performance.
    Fig 8: Removing Throttle Body
    G01485382Courtesy of GENERAL MOTORS CORP.
  21. Remove the upper intake manifold gasket.
  22. Clean and inspect the upper intake manifold.
    Fig 9: Removing Upper Intake Manifold Gasket
    G01485383Courtesy of GENERAL MOTORS CORP.
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