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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1218 (Engine Mechanical - 3.8L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Intake Manifold Replacement - Lower (L67) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2003 Pontiac Grand Prix. However, it is still accessible from the selected car via links, so may be relevant.
  1. Drain the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
  2. Remove the supercharger. Refer to SUPERCHARGER REPLACEMENT  .
  3. 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) in Engine Cooling.
    Fig 1: Removing Radiator Inlet Hose From Water Outlet Housing (Lower L67)
    G02083558Courtesy of GENERAL MOTORS CORP.
  4. Remove the exhaust gas recirculation (EGR) outlet pipe bolt from the lower intake manifold.
  5. Remove the EGR outlet pipe from the lower intake manifold.
  6. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
    Fig 2: Removing EGR Outlet Pipe
    G02083559Courtesy of GENERAL MOTORS CORP.
  7. Remove the lower intake manifold bolts.
  8. Remove the lower intake manifold. The coolant bypass tube will release from the intake manifold as the manifold is removed.
  9. Remove the lower intake manifold seals.
  10. Remove the lower intake manifold gaskets.
  11. If replacing the lower intake manifold, remove the water outlet housing and the thermostat.
  12. If replacing the lower intake manifold, remove the ECT sensor.
  13. Inspect the flatness of the inlet flanges.
  14. Clean the lower intake manifold mating surfaces.
  15. Clean the intake manifold bolts and the bolt holes of the adhesive compound.
    Fig 3: Removing Lower Intake Manifold
    G02083560Courtesy of GENERAL MOTORS CORP.
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