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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1198 (Engine Mechanical - 3.8L (On-Vehicle)) >> Repair Instructions >> Intake Manifold Replacement - Lower (L36) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2002 Pontiac Grand Prix. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the evaporative emissions (EVAP) canister purge solenoid.
    Fig 1: EVAP Canister Purge Solenoid
    G01703200Courtesy of GENERAL MOTORS CORP.
    NOTE: The two bolts which fasten the lower intake manifold to the cylinder head are accessible only after the upper intake is removed. The bolts are located in the right front and left rear corners of the lower intake manifold. Remove the upper intake manifold to service the lower intake.
  2. Remove the upper intake manifold. Refer to Intake Manifold Replacement - Upper .
  3. Remove the generator brace.
  4. Remove the drive belt tensioner with the heater water bypass inlet pipe. Refer to Drive Belt Tensioner Replacement (L36)  or Drive Belt Tensioner Replacement (L67) .
    Fig 2: Drive Belt Tensioner
    G01703201Courtesy of GENERAL MOTORS CORP.
  5. Remove the exhaust gas recirculation (EGR) outlet pipe bolt from the lower intake manifold.
  6. Remove the EGR outlet pipe from the lower intake manifold.
    Fig 3: EGR Outlet Pipe
    G01703202Courtesy of GENERAL MOTORS CORP.
  7. Remove the radiator inlet hose from the water outlet housing. Refer to RADIATOR HOSE REPLACEMENT - INLET (3.1 L) or RADIATOR HOSE REPLACEMENT - INLET (3.8L) .
    Fig 4: Radiator Inlet Hose
    G01703203Courtesy of GENERAL MOTORS CORP.
  8. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
    Fig 5: ECT Sensor Electrical Connector
    G01703204Courtesy of GENERAL MOTORS CORP.
  9. Remove the generator brace bracket bolts.
  10. Remove the generator brace bracket.
    Fig 6: Generator Brace Bracket
    G01703205Courtesy of GENERAL MOTORS CORP.
  11. Remove the lower intake manifold bolts.
  12. Remove the lower intake manifold.
    Fig 7: Lower Intake Manifold
    G01703206Courtesy of GENERAL MOTORS CORP.
  13. Remove the lower intake manifold seals.
    Fig 8: Lower Intake Manifold Seals
    G01703207Courtesy of GENERAL MOTORS CORP.
  14. Remove the lower intake manifold gaskets.
    Fig 9: Lower Intake Manifold Gaskets
    G01703208Courtesy of GENERAL MOTORS CORP.
  15. If replacing the lower intake manifold, remove the water outlet housing bolt, stud and the water outlet housing.
  16. If replacing the lower intake manifold, remove the ECT sensor.
  17. Inspect the flatness of inlet flanges.
  18. Clean the intake manifold mating surfaces.
  19. Clean the intake manifold bolts and bolt holes of adhesive compound.
    Fig 10: ECT Sensor
    G01703209Courtesy of GENERAL MOTORS CORP.
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