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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1094 (Engine Mechanical (Repair Instructions 1 Of 5) - 3.6L (Ly7)) >> Repair Instructions (On-Vehicle Part 1) >> Intake Manifold Replacement - Lower >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2004 Buick Rendezvous. However, it is still accessible from the selected car via links, so may be relevant.
  1. Turn the ignition OFF.
  2. Remove the air inlet duct. Refer to Air Cleaner Intake Duct Replacement in Engine Controls - 3.6L (LY7).
  3. Relieve the fuel pressure. Refer to Fuel Pressure Relief Procedure in Engine Controls - 3.6L (LY7).
  4. Disconnect the fuel pressure and evaporative emission (EVAP) hoses from the engine. Refer to Quick Connect Fitting(s) Service (Metal Collar) and to Quick Connect Fitting(s) Service (Plastic Collar) in Engine Controls - 3.6L (LY7).
  5. Disconnect the barometric pressure (BARO) sensor electrical connector.
    6. IMPORTANT: Do NOT disconnect the engine control module (ECM) electrical connectors.
  6. Remove the ECM bracket with the ECM and reposition aside.
  7. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  8. Disconnect the intermediate steering shaft from the steering gear. Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column.
  9. Remove and reposition the front portion of the front fender liners in order to gain access to the frame front bolts. Refer to Front Fender Liner Replacement in Body Front End.
  10. Lower the vehicle.
    11. Fig 1: Supporting Powertrain With Floor Jack
    GM628909Courtesy of GENERAL MOTORS CORP.
  11. Position a floor jack at the front center section of the frame in order to support the powertrain.
  12. Remove the frame front bolts.
  13. Carefully lower the powertrain or raise the vehicle enough to provide access.
    14. Fig 2: Purge Solenoid Electrical Connector
    GM1394073Courtesy of GENERAL MOTORS CORP.
  14. Disconnect the purge solenoid electrical connector.
    15. Fig 3: Identifying Wiring Harness Bracket Bolts On Right Side Of Intake Manifold
    GM1394052Courtesy of GENERAL MOTORS CORP.
  15. Remove the wiring harness from the right side of the intake manifold.
    16. Fig 4: View Of Fuel Injector Electrical Connector
    GM1394055Courtesy of GENERAL MOTORS CORP.
  16. Disconnect the fuel injector electrical connector.
    17. Fig 5: Locating Intake Manifold Runner Control Solenoid Electrical Connector
    GM1394037Courtesy of GENERAL MOTORS CORP.
  17. Disconnect the intake manifold runner control solenoid electrical connector.
    18. Fig 6: Identifying Throttle Body Electrical Connector
    GM1394050Courtesy of GENERAL MOTORS CORP.
  18. Remove the throttle body electrical connector.
  19. Remove the brake booster vacuum hose from the intake manifold.
    20. Fig 7: Locating PCV Dirty Air Tube
    GM1394081Courtesy of GENERAL MOTORS CORP.
  20. Remove the positive crankcase ventilation (PCV) hose from the intake manifold and the cylinder head.
    21. Fig 8: Identifying Intake Manifold Bolts
    GM1401464Courtesy of GENERAL MOTORS CORP.
  21. Remove the intake manifold bolts (1-6).
    22. Fig 9: View Of Intake Manifold
    GM1394084Courtesy of GENERAL MOTORS CORP.
  22. Remove the intake manifold.
  23. Disassemble the intake manifold as necessary. Refer to Intake Manifold Disassemble .
  24. Clean and inspect the intake manifold and the sealing surfaces. Refer to Intake Manifold Cleaning and Inspection .
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