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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1400 (Engine Mechanical - 3.1L V6 - VIN (J)) >> Repair Instructions >> On-Vehicle repair Instructions >> Intake Manifold Replacement - Lower >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2003 Buick Century. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE Battery.
  2. Remove the upper intake manifold. Refer to INTAKE MANIFOLD REPLACEMENT - UPPER  .
  3. Remove the left valve rocker arm cover. Refer to VALVE ROCKER ARM COVER REPLACEMENT - LEFT  .
  4. Remove the right valve rocker arm cover. Refer to VALVE ROCKER ARM COVER REPLACEMENT - RIGHT  .
  5. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
    Fig 1: Disconnecting Engine Coolant Temperature Sensor Electrical Connector
    G01967858Courtesy of GENERAL MOTORS CORP.
  6. Disconnect and remove the fuel injector and the manifold absolute pressure (MAP) sensor wiring harnesses.
    Fig 2: Removing Fuel Injector & Manifold Absolute Pressure Sensor Wiring Harnesses
    G01967859Courtesy of GENERAL MOTORS CORP.
  7. Remove the fuel pipe clip bolt.
    Fig 3: Removing Fuel Pipe Clip Bolt
    G01967860Courtesy of GENERAL MOTORS CORP.
  8. Remove the fuel pipe clip.
    Fig 4: Removing Fuel Pipe Clip
    G01967861Courtesy of GENERAL MOTORS CORP.
  9. Remove the fuel feed pipe from the fuel injector rail. Refer to FUEL LINE DISCONNECT FITTINGS in Removal & Installation.
    Fig 5: Removing Fuel Feed Pipe From Fuel Injector Rail
    G01967862Courtesy of GENERAL MOTORS CORP.
  10. Remove the fuel return pipe from the fuel injector rail. Refer to FUEL LINE DISCONNECT FITTINGS in Removal & Installation.
    Fig 6: Removing Fuel Return Pipe From Fuel Injector Rail
    G01967863Courtesy of GENERAL MOTORS CORP.
  11. Remove the fuel injector rail. Refer to FUEL RAIL & INJECTORS in Removal & Installation.
    Fig 7: Removing Fuel Injector Rail
    G01967864Courtesy of GENERAL MOTORS CORP.
  12. Remove the power steering pump from the front engine cover and reposition. Refer to POWER STEERING PUMP REPLACEMENT (3.1L) in Power Steering System.
  13. Remove the heater inlet pipe nut.
    Fig 8: Removing Heater Inlet Pipe With Heater Hose From Lower Intake Manifold
    G01967865Courtesy of GENERAL MOTORS CORP.
  14. Remove the heater inlet pipe with heater hose from the lower intake manifold and reposition.
  15. Remove the radiator inlet hose from the engine. Refer to RADIATOR HOSE REPLACEMENT - INLET (3.1L) in Engine Cooling.
  16. Remove the thermostat bypass hose from the thermostat bypass pipe and lower intake manifold pipe.
    Fig 9: Removing Thermostat Bypass Hose From Thermostat Bypass Pipe & Lower Intake Manifold Pipe
    G01967866Courtesy of GENERAL MOTORS CORP.
  17. Remove the lower intake manifold bolts.
    Fig 10: Removing Lower Intake Manifold & Bolts
    G01967867Courtesy of GENERAL MOTORS CORP.
  18. Remove the lower intake manifold.
  19. Remove the valve rocker arms and pushrods. Refer to VALVE ROCKER ARM AND PUSH ROD REPLACEMENT  .
  20. Remove the lower intake manifold gaskets and seals.
    Fig 11: Removing Lower Intake Manifold Gaskets
    G01967868Courtesy of GENERAL MOTORS CORP.
  21. Clean the lower intake manifold gasket mating surfaces.
  22. Remove and clean all the RTV sealant from the lower intake manifold and the engine block (1).
  23. Remove the ECT sensor.
    Fig 12: Removing Engine Coolant Temperature Sensor
    G01967869Courtesy of GENERAL MOTORS CORP.
  24. Remove the water outlet bolts.
  25. Remove the water outlet.
    Fig 13: Removing Water Outlet & Bolts
    G01967870Courtesy of GENERAL MOTORS CORP.
  26. Remove the thermostat.
    Fig 14: Removing Thermostat
    G01967871Courtesy of GENERAL MOTORS CORP.
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