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 outlet duct from the throttle body. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
3. Disconnect the accelerator control cable from the throttle shaft and the accelerator control cable bracket. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
4. 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.
5. Remove the PCV valve hose assembly from the intake manifold and the valve rocker arm cover.
   Fig 1: Removing PCV Valve Hose Assembly From Intake Manifold - Upper Intake Manifold

   Courtesy of GENERAL MOTORS CORP.
6. Remove the nut holding the A/C hose bracket, if equipped to the intake manifold stud.
7. Remove the A/C hose bracket from the stud.
   Fig 2: Removing A/C Hose Bracket From Stud - Upper Intake Manifold

   Courtesy of GENERAL MOTORS CORP.
8. Remove the nut holding the engine wiring harness bracket to the intake manifold stud.
9. Remove the engine wiring harness bracket from the stud.
10. 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 - Upper Intake Manifold

      Courtesy of GENERAL MOTORS CORP.
11. 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 - Upper Intake Manifold

      Courtesy of GENERAL MOTORS CORP.
12. Remove the engine wiring harness bracket from the stud at the EVAP canister purge solenoid valve.
13. Move and secure the engine wiring harness out of the way.
14. Remove the EVAP canister purge valve to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
    Fig 5: Removing Engine Wiring Harness Bracket From EVAP Canister Purge Solenoid Valve Stud

    Courtesy of GENERAL MOTORS CORP.
15. Disconnect the vacuum hose from the intake manifold.
    Fig 6: Disconnecting Vacuum Hose From Intake Manifold

    Courtesy of GENERAL MOTORS CORP.
16. Remove the bolt holding the transmission fluid filler tube to the accelerator control cable bracket.
    Fig 7: Removing Bolt From Transmission Fluid Filler Tube

    Courtesy of GENERAL MOTORS CORP.
17. Remove the accelerator control cable bracket from the throttle body and the intake manifold.
    Fig 8: Removing Accelerator Control Cable Bracket From Throttle Body And Intake Manifold

    Courtesy of GENERAL MOTORS CORP.
18. Remove the fuel lines from the fuel meter body assembly. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
19. Remove the studs for the upper intake manifold.
20. Remove the upper intake manifold.
    Fig 9: Removing Studs And Upper Intake Manifold

    Courtesy of GENERAL MOTORS CORP.
21. Remove the upper intake manifold gasket from the groove.
    Fig 10: Removing Upper Intake Manifold Gasket From Groove

    Courtesy of GENERAL MOTORS CORP.
22. Discard the gasket.
23. Remove the seal from the fuel meter body assembly.
    Fig 11: Removing Seal From Fuel Meter Body Assembly

    Courtesy of GENERAL MOTORS CORP.
24. Discard the seal.

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

25. Clean all sealing surfaces and the inside of the upper intake manifold with a shop towel and cleaning solvent.
26. 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
27. If replacing the upper intake manifold, turn and remove the PCV valve cover from the upper intake manifold.
    Fig 12: Removing PCV Valve Cover From Upper Intake Manifold

    Courtesy of GENERAL MOTORS CORP.
28. Remove and discard the seal.
29. Remove the throttle body if replacing the upper intake manifold. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
30. Remove the MAP sensor if replacing the upper intake manifold. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.