Removal Procedure

Important:  You do not have to remove the upper intake manifold in order to remove the lower intake manifold.

1. Remove the engine cover. Refer to Engine Cover Replacement in Interior Trim .
2. Remove the air cleaner assembly.
3. Remove the coolant reservoir bolt and set the reservoir aside.
4. Disconnect the positive crankcase ventilation (PCV) tube from the air cleaner outlet duct.
   Fig 1: Disconnecting PCV Tube

   Courtesy of GENERAL MOTORS CORP.
5. Remove the retaining nut (1) from the air cleaner outlet.
6. Remove the air cleaner outlet duct (2) from the throttle body assembly.
7. Disconnect the accelerator control cable from the throttle shaft and the accelerator control cable bracket.
8. Disconnect the cruise control cable, if equipped, from the throttle shaft and the accelerator control cable bracket. Refer to Cruise Control Cable Replacement in Cruise Control .
   Fig 2: Removing Retaining Nut & Air Cleaner Outlet Duct

   Courtesy of GENERAL MOTORS CORP.
9. Remove the PCV valve hose assembly from the intake manifold and the valve rocker arm cover.
   Fig 3: Removing PCV Valve Hose Assembly

   Courtesy of GENERAL MOTORS CORP.
10. Disconnect the following electrical connectors:
    • The fuel meter body assembly connector (1)
    • The EVAP canister purge solenoid valve (2)
    • The manifold absolute pressure (MAP) sensor (3)
      Fig 4: Disconnecting Fuel Meter Body Assembly Connector, EVAP Canister Purge Solenoid Valve & MAP Sensor

      Courtesy of GENERAL MOTORS CORP.
11. Disconnect the following electrical connectors:
    • The throttle position (TP) sensor (1)
    • The idle air control (IAC) motor (2)
    • The engine coolant temperature (ECT) gage sensor (3)
    • The A/C high pressure switch (4), if equipped
      Fig 5: Disconnecting TP Sensor, IAC Motor, ECT Gage Sensor & A/C High Pressure Switch

      Courtesy of GENERAL MOTORS CORP.
12. Remove the engine wiring harness bracket from the intake manifold stud.
13. Move and secure the engine wiring harness out of the way.
    Fig 6: Removing Engine Wiring Harness Bracket

    Courtesy of GENERAL MOTORS CORP.
14. Disconnect the A/C vacuum hose from the intake manifold.
15. Remove the power brake booster vacuum hose bracket and nut from the intake manifold stud.
16. Disconnect the power brake booster vacuum hose from the intake manifold.
    Fig 7: Disconnecting Vacuum Hoses & Removing Bracket

    Courtesy of GENERAL MOTORS CORP.
17. Remove the accelerator control cable bracket from the throttle body and the intake manifold.
18. Remove the EVAP canister purge solenoid. Refer to EVAP CANISTER PURGE VALVE .
19. Remove the fuel lines from the fuel meter body assembly.
20. Remove the distributor cap. Refer to DISTRIBUTOR .
21. Remove the ignition control module. Refer to IGNITION CONTROL MODULE .
    Fig 8: Removing Accelerator Control Cable Bracket

    Courtesy of GENERAL MOTORS CORP.
22. Remove the studs for the upper intake manifold.
23. Remove the upper intake manifold.
    Fig 9: Removing Studs & Upper Intake Manifold

    Courtesy of GENERAL MOTORS CORP.
24. Remove the upper intake manifold gasket from the groove.
25. Discard the gasket.
    Fig 10: Removing Upper Intake Manifold Gasket

    Courtesy of GENERAL MOTORS CORP.
26. Remove the seal from the fuel meter body assembly.
27. Discard the seal.

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

28. Clean all sealing surfaces and the inside of the upper intake manifold with a shop towel and cleaning solvent.
29. 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
      Fig 11: Removing Seal From Fuel Meter Body Assembly

      Courtesy of GENERAL MOTORS CORP.
30. If replacing the upper intake manifold, turn and remove the power brake booster vacuum tube fitting from the upper intake manifold.
31. Remove and discard the seal.
    Fig 12: Turning & Removing Power Brake Booster Vacuum Tube Fitting

    Courtesy of GENERAL MOTORS CORP.
32. If replacing the upper intake manifold, turn and remove the PCV valve cover from the upper intake manifold.
33. Remove and discard the seal.
34. Remove the throttle body if replacing the upper intake manifold. Refer to THROTTLE BODY .
35. Remove the MAP sensor if replacing the upper intake manifold. Refer to MANIFOLD ABSOLUTE PRESSURE SENSOR .
    Fig 13: Turning & Removing PCV Valve Cover

    Courtesy of GENERAL MOTORS CORP.