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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1095 (Engine Mechanical - 3.4L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Intake Manifold Replacement - Upper >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2004 Pontiac Aztek and 2004 Buick Rendezvous. However, it is still accessible from the selected car via links, so may be relevant.
IMPORTANT: The fuel injector wiring harness connectors must be connected to their respective fuel injectors. Failure to connect the fuel injector connectors to their respective fuel injectors may result in excessive exhaust emissions and poor engine performance.
  1. Drain the engine coolant from the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling.
  2. Remove the throttle body air inlet duct. Refer to Air Cleaner Intake Duct Replacement in Engine Controls - 3.4L.
  3. Remove the accelerator control and cruise control cables with bracket from the throttle body. Refer to Accelerator Controls Cable Replacement in Engine Controls - 3.4L.
  4. Disconnect the wiring harness connectors from the following throttle body components:
    • Throttle Position (TP) sensor
    • Idle Air Control (IAC) valve
  5. Disconnect the engine left side spark plug wires. Refer to Spark Plug Wire Replacement in Engine Electrical.
  6. Disconnect the engine left side spark plug wire harness attachment clip. Refer to Spark Plug Wire Replacement in Engine Electrical.
  7. Disconnect the throttle body heater hoses. Refer to Throttle Body Heater Hose Replacement - Inlet and Throttle Body Heater Hose Replacement - Outlet in Engine Cooling.
    8. Fig 1: Vacuum Hoses To EVAP Purge Valve
    GM261279Courtesy of GENERAL MOTORS CORP.
  8. Disconnect the vacuum hoses from the evaporative emission (EVAP) canister purge solenoid valve.
  9. Remove the EVAP canister purge solenoid valve. Refer to Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement in Engine Controls - 3.4L.
    10. Fig 2: Locating Ignition Coil Bracket
    GM261282Courtesy of GENERAL MOTORS CORP.
  10. Remove the ignition coil bracket.
    11. Fig 3: View Of Manifold Air Pressure (MAP) Sensor
    GM190605Courtesy of GENERAL MOTORS CORP.
  11. Disconnect the wiring harness from the manifold air pressure (MAP) sensor.
    12. Fig 4: Locating Vacuum Harness
    GM248103Courtesy of GENERAL MOTORS CORP.
  12. Disconnect the vacuum harness from the MAP sensor and the upper intake manifold.
    13. Fig 5: Identifying Emission Control Vacuum Harness
    GM261271Courtesy of GENERAL MOTORS CORP.
  13. Disconnect and remove the emission control vacuum harness.
  14. Disconnect the vacuum brake booster hose from the upper intake manifold.
  15. Disconnect the vacuum hose connections from the upper intake manifold:
    • Heating, Ventilation and Air Conditioning (HVAC) vacuum source hose
    • Fuel pressure regulator
  16. Remove the exhaust gas recirculation (EGR) valve. Refer to Exhaust Gas Recirculation (EGR) Valve Replacement in Engine Controls - 3.4L.
  17. Remove the MAP sensor and the bracket. Refer to Manifold Absolute Pressure (MAP) Sensor Replacement in Engine Controls - 3.4L.
  18. Remove generator through bolt bracket.
    19. Fig 6: View Of Upper Intake Manifold Studs And Bolts
    GM261259Courtesy of GENERAL MOTORS CORP.
  19. Remove the upper intake manifold studs and bolts.
    20. Fig 7: Upper Intake Manifold
    GM261260Courtesy of GENERAL MOTORS CORP.
  20. Remove the upper intake manifold.
    21. Fig 8: View Of Throttle Body
    GM61855Courtesy of GENERAL MOTORS CORP.
  21. If replacing the intake manifold, remove the throttle body. Refer to Throttle Body Assembly Replacement in Engine Controls - 3.4L.
    22. Fig 9: Identifying Upper Intake Manifold Gasket
    GM261261Courtesy of GENERAL MOTORS CORP.
  22. Remove the upper intake manifold gasket.
  23. Clean and inspect the upper intake manifold. Refer to Intake Manifold Cleaning and Inspection - Upper  in the Engine Unit Repair Manual.
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