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Removal & Installation (4.3L - Upper)

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NOTE: It is not necessary to remove the upper intake manifold in order to remove the intake manifold assembly.
  1. Remove the engine cover. See ENGINE COVER . Disconnect the PCV tube from the air cleaner outlet duct. Remove the retaining nut from the air cleaner outlet. Remove the air cleaner outlet duct from the throttle body assembly. Disconnect the harness connector of the Intake Air Temperature (IAT) sensor. Loosen the air cleaner outlet duct from the Mass Air Flow (MAF) sensor. Remove the air cleaner outlet duct. Remove the air cleaner assembly. Disconnect the accelerator control cable from the throttle shaft and the accelerator control cable bracket. Disconnect the cruise control cable (if equipped) from the throttle shaft and the accelerator control cable bracket.
  2. Remove the PCV valve hose assembly from the intake manifold and the valve rocker arm cover. Disconnect the fuel meter body assembly connector, EVAP canister purge solenoid valve connector, Manifold Absolute Pressure (MAP) sensor connector, Throttle Position (TP) sensor connector, Idle Air Control (IAC) motor connector, Engine Coolant Temperature (ECT) gauge sensor connector and A/C high pressure switch connector (if equipped). Remove the engine wiring harness bracket from the intake manifold stud. Move and secure the engine wiring harness out of the way.
  3. Disconnect the A/C vacuum hose from the intake manifold. Remove the power brake booster vacuum hose bracket and nut from the intake manifold stud. Disconnect the power brake booster vacuum hose from the intake manifold. Remove the accelerator control cable bracket from the throttle body and the intake manifold. Remove the EVAP canister purge solenoid. See EVAP CANISTER PURGE VALVE REMOVAL & INSTALLATION  in EVAPORATIVE EMISSIONS SYSTEM under EMISSIONS SYSTEMS & SUB-SYSTEMS.
  4. Remove the fuel lines from the fuel meter body assembly. Remove the distributor cap. Remove the ignition control module. Remove the studs for the upper intake manifold. Remove the upper intake manifold. Remove the upper intake manifold gasket from the groove. Discard the gasket. Remove the seal from the fuel meter body assembly. Discard the seal.
    5. WARNING: Do not immerse the assembled upper intake manifold in cleaning solvent. Clean all sealing surfaces and the inside of the upper intake manifold with a shop towel and cleaning solvent.
  5. Inspect the upper intake manifold for cracks or other damage to the exterior, Cracking or damage to the gasket grooves, loose or damaged bolt hole thread inserts. If replacing the upper intake manifold, remove the MAP sensor, the throttle body, the power brake booster vacuum tube fitting and the PCV valve cover from the upper intake manifold. Remove and discard the seal.
  6. If replacing the upper intake manifold, install all components removed from upper intake manifold, using NEW seals lubricated with clean engine oil as necessary. Install a NEW upper intake manifold to lower intake manifold gasket in the groove of the upper intake manifold. Install the upper intake manifold onto the lower intake manifold.
  7. If reusing the fasteners, apply Threadlock (GM 12345382) to the threads of the upper intake manifold attaching bolts. Install the upper intake manifold attaching studs. Install the fuel lines to the fuel meter body assembly. To complete installation, reverse removal procedure. See TORQUE SPECIFICATIONS . Install the engine cover.
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