Removal & Installation (Van)

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2002 GMC Savana Special, 2002 GMC Savana Camper Special, 2002 GMC Savana, 2002 GMC C3500 HD, and 2002 Chevrolet RV Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

Disconnect the battery negative cable from the battery. Remove engine cover from vehicle. See ENGINE COVER . Remove air cleaner assembly. Remove the air intake duct from the turbocharger.
Remove the upper intake manifold bolts. Remove the upper intake manifold. Remove the gaskets from the lower intake manifold. Remove the seal from the turbocharger.
The lower intake comes in two sections. If only the right side is being removed, go to step 5. If the left side or both sides are being removed, remove the transmission oil level indicator tube upper section from the upper intake manifold. Remove the oil level indicator from the tube. Remove the nut retaining the oil level indicator to the thermostat crossover. Separate the upper section of the oil level indicator tube from the lower section. If equipped with rear Air Conditioning (A/C), remove the rear A/C pipe from the A/C compressor. See appropriate MANUAL A/C-HEATER SYSTEMS article.
Remove the nuts retaining the rear A/C pipe brackets from the upper intake manifold (if equipped). Position the rear A/C pipe our of the way. Drain the engine coolant. See DRAINING & FILLING under COOLING SYSTEMS. Remove the upper radiator hose. Disconnect the gray engine harness electrical connector. Remove the electrical harness and retaining brackets from the upper intake manifold (if needed). Remove the nuts retaining the fuel pipe brackets. Remove the bracket for retaining the CDR valve from the right side lower intake manifold studs. If removing both sides of lower intake manifold, go to next step. If removing only the left side lower intake manifold, go to step 8.
The sensors and the solenoids attached to the lower intake manifold require removal in order to prevent damage when cleaning with solvent cleaning. Remove the CDR valve. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. Remove the IAT sensor.
Disconnect the boost sensor electrical connector by releasing the locking tab. Remove the boost sensor retaining bolts. Remove the boost sensor. Remove the gasket. Disconnect the glow plug relay electrical connectors by releasing the locking tab. Remove the hold down nuts on the glow plug relay power supply terminals. Remove the glow plug relay power supply terminals. Remove the glow plug relay retaining nuts. Remove the glow plug relay.
Disconnect the wastegate solenoid wiring harness connector by releasing the locking tab. Remove the vacuum hose harness. Remove the wastegate solenoid retaining bolts. Remove the wastegate solenoid. Remove the wastegate solenoid mounting bracket retaining nuts. Remove the wastegate solenoid mounting bracket. Remove the electrical harness retaining clips. Position the engine wiring harness out of the way.

NOTE: Install a new "O" ring onto the turbocharger inlet housing. Lightly lubricate the "O" ring with clean engine oil.

Remove the lower intake manifold bolts. Remove the lower intake manifold and gaskets from the cylinder heads. Inspect and clean the sealing surfaces. Install the new gaskets onto the cylinder heads. Install the intake manifolds. Apply Teflon Sealer (GM 1236004) on the threads of the studs that are second to the end on both intake manifolds. There are a total of four studs that require the teflon sealer. Apply Threadlocker (GM 12345382) on the threads of the remaining studs. Install the intake manifold studs. Tighten intake fasteners from center out. To complete installation, reverse removal procedure. Tighten fasteners properly. See TORQUE SPECIFICATIONS . Fill the engine coolant. See DRAINING & FILLING under COOLING SYSTEMS. Recharge the A/C system, if required.