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Home >> Chevrolet >> 2005 >> Chevy Express H1500, Van Passenger >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 2 (Engine Mechanical - 4.3L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Intake Manifold Replacement - Lower >> Removal Procedure

Removal Procedure

WARNING: This page is about a different variant/trim than selected.
IMPORTANT: You do not have to remove the upper intake manifold in order to remove the lower intake manifold.
  1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  2. Drain the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling.
  3. Remove the upper intake. Refer to Intake Manifold Replacement - Upper .
    4. Fig 1: A/C Compressor, Exhaust Gas Recirculation (EGR) Connector & Ground Wire
    GM532777Courtesy of GENERAL MOTORS CORP.
  4. Disconnect the A/C compressor (1) and the exhaust gas recirculation (EGR) connector (2).
  5. Remove the ground wire (4) from the stud at the water outlet.
    6. Fig 2: Identifying Radiator Inlet Hose
    GM71614Courtesy of GENERAL MOTORS CORP.
  6. Remove the radiator inlet hose at the water outlet. Refer to Radiator Hose Replacement - Inlet in Engine Cooling.
  7. Remove the heater hose from the intake manifold. Refer to Heater Hose Replacement - Inlet and Heater Hose Replacement - Outlet in Heating, Ventilation and Air Conditioning.
  8. Remove the water pump inlet hose from the intake manifold.
    9. Fig 3: View Of Accelerator Cable Bracket
    GM398027Courtesy of GENERAL MOTORS CORP.
  9. Remove the accelerator control cable bracket from the throttle body and the intake manifold.
  10. Remove the distributor. Refer to Distributor Replacement in Engine Controls-4.3L.
  11. Remove the spark plug wire harness retainer from the EGR valve inlet pipe.
    12. Fig 4: View Of Power Steering Pump Bracket
    GM340090Courtesy of GENERAL MOTORS CORP.
  12. In order to remove the front intake manifold bolt, perform the following:
    1. Remove the A/C compressor discharge hose from the vehicle. Refer to Discharge Hose Replacement (4.8L, 5.3L, 6.0L ) in Heating, Ventilation, and Air Conditioning.
    2. Remove the A/C compressor suction hose from the vehicle. Refer to Suction Hose Replacement in Heating, Ventilation, and Air Conditioning.
    3. Remove the drive belt. Refer to Drive Belt Replacement .
    4. Loosen the nut for the power steering pump rear bracket.
    5. Remove the bolts and the nut for the power steering pump mounting bracket.
    6. Leave the A/C compressor, if equipped, and the power steering pump on the bracket.
    7. Slide the power steering pump bracket forward to access the bolt at the front of the intake manifold.
    13. Fig 5: Intake Manifold Assembly & Bolts
    GM31510Courtesy of GENERAL MOTORS CORP.
  13. Remove the engine coolant temperature (ECT) sensor wire connector, if equipped, from the engine wiring harness bracket.
  14. Remove the lower intake manifold bolts.
    15. IMPORTANT: The intake manifold may be removed as an assembly. Do not remove the specific intake manifold components unless component service is required.
    Do not allow dirt or debris to enter the fuel system. Ensure that the ends of the fuel system are properly sealed.
    Do not disassemble the central sequential fuel injection (SFI) unit, unless service is required.
  15. Remove the intake manifold assembly.
  16. Remove and discard the lower intake manifold gaskets.
  17. Clean all sealing surfaces and the intake manifold. Refer to Intake Manifold Cleaning and Inspection .
  18. If the intake manifold requires replacement refer to Intake Manifold Disassemble  and Intake Manifold Assemble .
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