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Intake Manifold: Removal

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2003 GMC Yukon XL, 2003 GMC Sierra, 2003 GMC Cab & Chassis Sierra, 2003 Chevrolet Suburban, and 2003 Chevrolet Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Loosen clamps at the throttle body and air cleaner.
  2. Remove air cleaner outlet duct.
  3. Loosen intake manifold sight shield bolt.
  4. Remove sight shield from bracket.
  5. Remove sight shield from bracket and nuts.
  6. Relieve fuel system pressure. See FUEL PRESSURE RELEASE .
  7. Disconnect fuel feed and return lines. See QUICK CONNECT FITTING SERVICE .
  8. Disconnect engine harness clips from the studs on the front of dash.
  9. Disconnect engine harness clip from the wheelhouse splash panel.
  10. Disconnect the pressure cycling switch, surge tank switch, and Mass Airflow (MAF) sensor harness connectors. See Figure.
  11. Reposition engine harness branch to top of engine.
  12. Remove the Connector Position Assurance (CPA) retainer at the ignition coil harness.
  13. Disconnect the Manifold Absolute Pressure (MAP) sensor, ignition coil harness, and Engine Coolant Temperature (ECT) sensor connectors. See Figure.
  14. Remove engine harness bolt and studs.
  15. Remove the CPA retainer at the ignition coil harness.
  16. Disconnect the generator, injector harness, ignition coil harness, Throttle Position (TP) sensor, Electronic Throttle Control (ETC), and purge valve solenoid connectors. See Figure.
  17. Reposition engine harness to drivers-side of engine compartment.
  18. Remove bypass valve vacuum hose from the intake manifold.
  19. Disconnect EGR valve harness connector. See Figure.
  20. Remove EGR pipe bolts at EGR adapter.
  21. Reposition EGR pipe.
  22. Remove and discard EGR valve pipe gasket.
  23. Remove fuel pressure regulator vacuum hose.
  24. Remove fuel rail studs, and fuel rail. See Figure.
  25. Remove intake manifold bolts, and remove intake manifold. See Figure.
  26. Remove and discard intake manifold side gaskets.
  27. Remove and discard intake manifold end seals.
  28. Remove splash shield.
  29. If replacing intake manifold, see INTAKE MANIFOLD  under OVERHAUL.
  30. Clean and inspect intake manifold. See INTAKE MANIFOLD  under OVERHAUL.
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