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Home >> Chevrolet >> 2007 >> Chevy Express G2500, Van Cargo, 6.6 6 >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 20 (Engine Mechanical - 4.3L) >> Repair Instructions - On Vehicle >> Upper Intake Manifold Replacement >> 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.
    Fig 1: PCV Valve Hose Assembly
    GM183399Courtesy of GENERAL MOTORS CORP.
  1. Remove the engine cover. Refer to Engine Cover Replacement .
  2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
  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.
    5. Fig 2: Locating Air Cleaner Outlet Retaining Nut
    GM35885Courtesy 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. Refer to Accelerator Control Cable Replacement .
  8. Disconnect the cruise control cable, if equipped, from the throttle shaft and the accelerator control cable bracket. Refer to Cruise Control Cable Replacement .
    9. Fig 3: Identifying Breather Tube
    GM172995Courtesy of GENERAL MOTORS CORP.
  9. Remove the PCV valve hose assembly from the intake manifold and the valve rocker arm cover.
    10. Fig 4: Fuel Meter Body Assembly Connector, EVAP Canister Purge Solenoid Valve & Manifold Absolute Pressure Sensor
    GM532770Courtesy 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)
    11. Fig 5: Throttle Position Sensor, Idle Air Control Motor, Engine Coolant Temperature Gage Sensor, & A/C High Pressure Switch
    GM532760Courtesy 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
    12. Fig 6: Engine Wiring Harness Bracket From Intake Manifold Stud
    GM339442Courtesy 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.
    14. Fig 7: Intake Manifold A/C Vacuum Hose
    GM374900Courtesy 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.
    17. Fig 8: View Of Accelerator Cable Bracket
    GM398027Courtesy 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 valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement .
  19. Remove the fuel lines from the fuel meter body assembly. Refer to Fuel Hose/Pipes Replacement - Engine Compartment .
  20. Remove the distributor cap. Refer to Distributor Replacement .
  21. Remove the ignition control module. Refer to Ignition Control Module Replacement .
    22. Fig 9: Upper Intake Manifold
    GM516794Courtesy of GENERAL MOTORS CORP.
  22. Remove the studs for the upper intake manifold.
  23. Remove the upper intake manifold.
    24. Fig 10: Intake Manifold Upper Gasket
    GM516790Courtesy of GENERAL MOTORS CORP.
  24. Remove the upper intake manifold gasket from the groove.
  25. Discard the gasket.
    26. Fig 11: Fuel Meter Body O-Ring Seal
    GM516773Courtesy of GENERAL MOTORS CORP.
  26. Remove the seal from the fuel meter body assembly.
  27. Discard the seal.
    28. 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
    30. Fig 12: Locating PCV Valve Cover
    GM516804Courtesy 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.
    32. Fig 13: Power Brake Booster Vacuum Fitting
    GM516797Courtesy 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 Assembly Replacement .
  35. Remove the MAP sensor if replacing the upper intake manifold. Refer to Manifold Absolute Pressure Sensor Replacement .
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