Removal Procedure

Important  : The upper intake does not have to be removed to remove the lower intake manifold.

1. Disconnect the breather tube at the air cleaner outlet duct.
   Fig 1: Breather Tube

   Courtesy of GENERAL MOTORS CORP.
2. Remove the air cleaner outlet duct retaining wingnut.
   Fig 2: Air Cleaner Outlet Duct Retaining Wingnut

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3. Disconnect the IAT sensor harness connector.
   Fig 3: IAT Sensor Harness Connector

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4. Remove the air cleaner outlet duct from the throttle body.
   Fig 4: Air Cleaner Outlet Duct

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5. Disconnect the accelerator cable from the throttle body.
   Fig 5: Accelerator Cable At Throttle Body

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6. Remove the accelerator cable from the accelerator control cable bracket.
   Fig 6: Accelerator Cable At Accelerator Control Cable Bracket

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7. Disconnect the cruise control cable, if equipped from the throttle shaft and the accelerator cable bracket. Refer to CRUISE CONTROL CABLE REPLACEMENT (4.3L) or CRUISE CONTROL CABLE REPLACEMENT (2.2L) .
8. Disconnect the vacuum hose from the intake manifold for the vacuum tank.
9. Remove the power brake booster vacuum hose.
   Fig 7: Vacuum Hose

   Courtesy of GENERAL MOTORS CORP.
10. Disconnect the following electrical connectors:
    • The A/C compressor clutch (1)
    • The A/C compressor cutoff switch (5), if equipped
    • The throttle position (TP) sensor (2)
    • The idle air control (IAC) motor (3)
    Fig 8: A/C Compressor Clutch, Cutoff Switch, TP Sensor & IAC Motor Electrical Connectors

    Courtesy of GENERAL MOTORS CORP.
11. Disconnect the following electrical connectors:
    • The fuel meter body assembly (1)
    • The manifold absolute pressure (MAP) sensor (3)
    • The EVAP canister purge solenoid valve (2)
12. Remove the engine wire harness clip from the accelerator cable bracket.
13. Move the engine wiring harness aside.
    Fig 9: Fuel Meter Body Assembly, MAP Sensor & EVAP Canister Purge Solenoid Valve Electrical Connectors

    Courtesy of GENERAL MOTORS CORP.
14. Remove the accelerator cable bracket from the throttle body and the intake manifold.
    Fig 10: Accelerator Cable Bracket

    Courtesy of GENERAL MOTORS CORP.
15. Remove the accelerator and cruise control cable bracket from the throttle body.

    Leave the accelerator and cruise control cables on the bracket.

    Fig 11: Accelerator & Cruise Control Cable Bracket

    Courtesy of GENERAL MOTORS CORP.
16. Remove the PCV valve hose assembly from the intake manifold and the valve rocker arm cover.
    Fig 12: PCV Valve Hose Assembly

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17. Remove the bracket for the engine wiring harness from the intake manifold stud.
18. Remove the fuel lines from the fuel meter body assembly.
19. Remove the EVAP canister purge solenoid valve. Refer to EVAP CANISTER PURGE SOLENOID .
    Fig 13: Engine Wiring Harness Bracket

    Courtesy of GENERAL MOTORS CORP.
20. Remove the studs for the upper intake manifold.
21. Remove the upper intake manifold.
    Fig 14: Upper Intake Manifold & Studs

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22. Remove the upper intake manifold gasket from the groove.
23. Discard the gasket.
    Fig 15: Upper Intake Manifold & Gasket

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24. Remove the seal from the fuel meter body assembly.
25. Discard the seal.

    Important  : Do not immerse the assembled upper intake manifold in cleaning solvent.

26. Clean all sealing surfaces and the inside of the upper intake manifold with a shop towel and cleaning solvent.
27. Inspect the upper intake manifold for the following:
    • Cracks or other damage to the exterior
    • Cracking or damage to the gasket grooves
    • Loose or damaged bolt hole thread inserts
    • Damage to the throttle body mounting surface
    Fig 16: Fuel Meter Body Assembly Seal

    Courtesy of GENERAL MOTORS CORP.
28. If replacing the upper intake manifold, turn and remove the power brake booster vacuum tube fitting from the upper intake manifold.
29. Remove and discard the seal.
    Fig 17: Power Brake Booster Vacuum Tube Fitting & Seal

    Courtesy of GENERAL MOTORS CORP.
30. If replacing the upper intake manifold, turn and remove the PCV valve cover from the upper intake manifold.
31. Remove and discard the seal.
32. Remove the throttle body if replacing the upper intake manifold. Refer to THROTTLE BODY .
33. Remove the MAP sensor if replacing the upper intake manifold. Refer to MANIFOLD ABSOLUTE PRESSURE SENSOR .
    Fig 18: PCV Valve Cover & Seal

    Courtesy of GENERAL MOTORS CORP.