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Home >> Chevrolet >> 2002 >> Monte Carlo LS >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical - 3.4L V6 - VIN (E) (On-Vehicle) >> Repair Instructions >> Intake Manifold (Lower) - Replacement >> Removal Procedure

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the upper intake manifold. Refer to Intake Manifold Replacement - Upper .
  3. Remove the left valve rocker arm cover. Refer to Valve Rocker Arm Cover (Left) - Replacement .
  4. Remove the right valve rocker arm cover. Refer to Valve Rocker Arm Cover (Right) - Replacement .
  5. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
    Fig 1: ECT Sensor
    G01806745Courtesy of GENERAL MOTORS CORP.
  6. Disconnect and remove the fuel injector and the manifold absolute pressure (MAP) sensor wiring harnesses.
    Fig 2: Fuel Injector & MAP Sensor Wiring Harness
    G01806746Courtesy of GENERAL MOTORS CORP.
  7. Remove the fuel pipe clip bolt.
    Fig 3: Fuel Pipe Clip Bolt
    G01806747Courtesy of GENERAL MOTORS CORP.
  8. Remove the fuel pipe clip.
    Fig 4: Fuel Pipe Clip
    G01806748Courtesy of GENERAL MOTORS CORP.
  9. Remove the fuel feed pipe from the fuel injector rail.
    Fig 5: Fuel Feed Pipe
    G01806749Courtesy of GENERAL MOTORS CORP.
  10. Remove the fuel return pipe from the fuel injector rail.
    Fig 6: Fuel Return Pipe
    G01806750Courtesy of GENERAL MOTORS CORP.
  11. Remove the fuel injector rail. Refer to FUEL RAIL & INJECTORS .
    12. Fig 7: Fuel Injector Rail
    G01806751Courtesy of GENERAL MOTORS CORP.
  12. Remove the power steering pump from the front engine cover and reposition.
  13. Remove the heater inlet pipe with heater hose from the lower intake manifold and reposition.
  14. Remove the radiator inlet hose from the engine.
    Fig 8: Radiator Inlet Hose
    G01806752Courtesy of GENERAL MOTORS CORP.
  15. Remove the thermostat bypass hose from the thermostat bypass pipe and lower intake manifold pipe.
    Fig 9: Thermostat Bypass Hose
    G01806753Courtesy of GENERAL MOTORS CORP.
  16. Remove the lower intake manifold bolts.
  17. Remove the lower intake manifold.
  18. Remove the valve rocker arms and pushrods. Refer to Valve Rocker Arm & Push Rod - Replacement .
  19. Remove the lower intake manifold gaskets and seals.
    20. Fig 10: Lower Intake Manifold
    G01806754Courtesy of GENERAL MOTORS CORP.
  20. Clean the lower intake manifold gasket mating surfaces.
    21. Fig 11: Lower Intake Manifold Gasket
    G01806755Courtesy of GENERAL MOTORS CORP.
  21. Remove and clean all the RTV sealant from the lower intake manifold and the engine block (1).
  22. Remove the ECT sensor.
    Fig 12: ECT Sensor
    G01806756Courtesy of GENERAL MOTORS CORP.
  23. Remove the water outlet bolts.
  24. Remove the water outlet.
    Fig 13: Water Outlet
    G01806757Courtesy of GENERAL MOTORS CORP.
  25. Remove the thermostat.
    Fig 14: Thermostat
    G01806758Courtesy of GENERAL MOTORS CORP.
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