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Home >> Chevrolet >> 2006 >> Silverado 1500 HD, 4WD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 10 (Engine Mechanical - 8.1L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Intake Manifold Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different variant/trim than selected.
IMPORTANT: The intake manifold, throttle body, fuel rail, and injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.
  1. Loosen the clamps at the throttle body and air cleaner.
  2. Remove the air cleaner outlet duct.
    Fig 1: View Of Air Cleaner Outlet Duct
    GM700979Courtesy of GENERAL MOTORS CORP.
  3. Unsnap the intake manifold sight shield from the stud.
  4. Remove the sight shield from the bracket.
    Fig 2: Intake Manifold Sight Shield
    GM843779Courtesy of GENERAL MOTORS CORP.
  5. Remove the sight shield bracket nuts (1) and bracket, if necessary.
  6. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure in Engine Controls - 8.1L.
  7. Disconnect the fuel feed and return pipes. Refer to Quick Connect Fitting(s) Service (Metal Collar) in Engine Controls - 8.1L.
  8. Disconnect the engine harness clips from the studs on the front of dash.
  9. Disconnect the engine harness clip from the wheelhouse splash shield.
  10. Disconnect the following electrical connectors:
    Fig 3: View Of MAF/IAT Sensor Electrical Connectors
    GM750582Courtesy of GENERAL MOTORS CORP.
    • Pressure cycling switch (1)
    • Surge tank switch (2)
    • Mass airflow (MAF) sensor (3)
  11. Reposition the engine harness branch to top of engine.
  12. Remove the connector position assurance (CPA) retainer at the ignition coil harness.
  13. Disconnect the following electrical connectors:
    Fig 4: View Of Ignition Coil, ECT And MAP Sensor Electrical Connectors
    GM750529Courtesy of GENERAL MOTORS CORP.
    • Manifold absolute pressure (MAP) sensor (1)
    • Ignition coil harness (2)
    • Engine coolant temperature (ECT) sensor (3)
  14. Remove the engine harness bolt and studs
  15. Remove the CPA retainer at the ignition coil harness.
  16. Disconnect the following electrical connectors:
    Fig 5: View Of Generator, Injector Harness, Ignition Coil Harness, ETC & Purge Valve Solenoid Electrical Connectors
    GM1235689Courtesy of GENERAL MOTORS CORP.
    • Generator (2)
    • Injector harness (3)
    • Ignition coil harness (4)
    • Electronic throttle control (ETC) (5)
    • Purge valve solenoid (1)
  17. Reposition the engine harness to the drivers side of the engine compartment.
  18. Remove the bypass valve vacuum hose (1) from the intake manifold.
    Fig 6: View Of Bypass Valve Vacuum Hose
    GM750614Courtesy of GENERAL MOTORS CORP.
  19. Disconnect the evaporative emission (EVAP) tube from the purge solenoid.
    Fig 7: View Of EVAP Purge Tube At Purge Solenoid
    GM843915Courtesy of GENERAL MOTORS CORP.
  20. Unclip the EVAP tube from the fuel rail.
    Fig 8: View Of EVAP Tube At Fuel Rail
    GM843918Courtesy of GENERAL MOTORS CORP.
  21. Disconnect the EVAP tube from the vent pipe at the rear of the engine.
  22. Remove the EVAP tube.
  23. If replacing the intake manifold, remove the fuel rail studs.
  24. Remove the fuel rail.
    Fig 9: View Of Fuel Injection Rail
    GM1198692Courtesy of GENERAL MOTORS CORP.
    25. IMPORTANT: Do not attempt to loosen the manifold by prying under the gasket surface with any tool.
    Fig 10: View Of Intake Manifold Bolts
    GM843795Courtesy of GENERAL MOTORS CORP.
  25. Remove the intake manifold bolts.
  26. Remove the intake manifold.
    Fig 11: View Of Intake Manifold
    GM843798Courtesy of GENERAL MOTORS CORP.
    27. IMPORTANT: The intake manifold gaskets are not reusable.
    Fig 12: View Of Intake Manifold Gaskets
    GM843815Courtesy of GENERAL MOTORS CORP.
  27. Remove and discard the intake manifold side gaskets.
  28. Remove and discard the intake manifold end seals.
    Fig 13: View Of Intake Manifold End Seals
    GM843823Courtesy of GENERAL MOTORS CORP.
    29. IMPORTANT: The splash shield is secured using a snap-in fit. Do not distort the splash shield. The splash shield is reusable.
    Fig 14: View Of Intake Manifold Splash Shield
    GM843827Courtesy of GENERAL MOTORS CORP.
  29. Remove the splash shield.
  30. If replacing the intake manifold, refer to Intake Manifold Disassemble .
  31. Clean and inspect the intake manifold. Refer to Intake Manifold Cleaning and Inspection .
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