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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> Engine Mechanical >> Engine Mechanical - 4.3L >> Repair Instructions >> On-Vehicle Repair Instructions >> Intake Manifold Replacement - Lower >> Removal Procedure

Removal Procedure

  1. Disconnect the battery negative cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Battery.
  2. Remove the engine cover. Refer to ENGINE COVER REPLACEMENT in Interior Trim.
  3. Drain the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
  4. Remove the air cleaner assembly. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
  5. Remove the air cleaner outlet duct from the throttle body assembly. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
  6. Disconnect the accelerator control cable from the throttle shaft and the accelerator control cable bracket. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
  7. Perform this step if the vehicle is equipped with a cruise control. Disconnect the cruise control cable from the throttle shaft, and from the accelerator control cable bracket. Refer to CRUISE CONTROL CABLE REPLACEMENT in Cruise Control.
  8. Disconnect PCV valve hose assembly from the intake manifold and the valve rocker arm cover.
    Fig 1: Disconnecting PCV Valve Hose Assembly From Intake Manifold And Valve Rocker Arm Cover
    G01643653Courtesy of GENERAL MOTORS CORP.
  9. Remove the nut holding the A/C hose bracket to the intake manifold stud, if equipped.
    Fig 2: Removing A/C Hose Bracket
    G01643654Courtesy of GENERAL MOTORS CORP.
  10. Remove the nut holding the engine wiring harness bracket to the intake manifold stud.
  11. Disconnect the following electrical connectors:
    • The A/C compressor clutch, if equipped (1)
    • The A/C high pressure cutoff switch, if equipped (5)
    • The throttle position (TP) sensor (2)
    • The idle air control (IAC) motor (3)
    • The fuel meter body assembly connector (4)
      Fig 3: Disconnecting Electrical Connectors - Lower Intake Manifold
      G01643655Courtesy of GENERAL MOTORS CORP.
  12. Disconnect the following electrical connectors:
    • The manifold absolute pressure (MAP) sensor (4)
    • The EVAP canister purge solenoid valve (1)
    Fig 4: Disconnecting MAP Sensor & EVAP Canister Purge Solenoid Valve Connectors
    G01643656Courtesy of GENERAL MOTORS CORP.
  13. Remove the ground wire from the stud at the water outlet.
  14. Remove the nut, and remove the engine wiring harness bracket from the stud, at the EVAP canister purge solenoid valve.
    Fig 5: Removing Engine Wiring Harness Bracket From EVAP Canister Purge Solenoid Valve Stud
    G01643657Courtesy of GENERAL MOTORS CORP.
  15. Move and secure the engine wire harness out of the way.
  16. Remove the EVAP canister purge valve. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
  17. Remove the radiator inlet hose at the water outlet. Refer to RADIATOR HOSE REPLACEMENT - INLET in Engine Cooling.
  18. Remove the heater hose from the intake manifold. Refer to HEATER HOSE REPLACEMENT - INLET in Heating Ventilation and Air Conditioning.
  19. Remove the water pump inlet hose from the intake manifold.
    Fig 6: Removing Water Pump Inlet Hose From Intake Manifold
    G01643658Courtesy of GENERAL MOTORS CORP.
  20. Disconnect the vacuum hose from the intake manifold.
    Fig 7: Disconnecting Vacuum Hose From Intake Manifold
    G01643659Courtesy of GENERAL MOTORS CORP.
  21. Remove the bolt holding the transmission fluid filler tube to the accelerator control cable bracket.
    Fig 8: Removing Bolt Holding Transmission Fluid Filler Tube To Accelerator Control Cable Bracket
    G01643660Courtesy of GENERAL MOTORS CORP.
  22. Remove the accelerator control cable bracket from the throttle body and the intake manifold.
  23. Remove the distributor. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
  24. Disconnect the fuel supply, and disconnect the return pipes, at the rear of the intake manifold. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
  25. Remove the ignition control module (ICM). Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
    Fig 9: Removing Accelerator Control Cable Bracket From Throttle Body And Intake Manifold
    G01643661Courtesy of GENERAL MOTORS CORP.
  26. In order to remove the front intake manifold bolt, perform the following steps:
    Fig 10: Removing Front Intake Manifold Bolt
    G01643662Courtesy of GENERAL MOTORS CORP.
    1. 26.1. Remove the drive belt. Refer to DRIVE BELT REPLACEMENT  .
    2. 26.2. Remove the A/C compressor side brace.
    3. 26.3. Loosen the nut for the power steering pump rear bracket.
    4. 26.4. Remove the oil filler tube bracket bolt and the oil filler tube.
    5. 26.5. Remove the bolts and the nut for the power steering pump mounting bracket.
    6. 26.6. Leave the A/C compressor, if equipped, and the power steering pump on the bracket.
    7. 26.7. Slide the power steering pump bracket forward to access the bolt at the front of the intake manifold.
  27. Remove the lower intake manifold. Refer to INTAKE MANIFOLD REPLACEMENT - LOWER  .
  28. Clean all sealing surfaces and the intake manifold. Refer to INTAKE MANIFOLD CLEANING AND INSPECTION  .
  29. If the intake manifold requires replacement, refer to INTAKE MANIFOLD DISASSEMBLE (LU3)  , and to INTAKE MANIFOLD ASSEMBLY (LU3)  .
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