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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1401 (Engine Mechanical - 3.8L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Intake Manifold Replacement - Lower (L36) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2003 Buick Regal. 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: Removing Evaporative Emissions Canister Purge Solenoid
    G01968423Courtesy 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  .
    Fig 2: Removing Thermostat Water Bypass Pipes
    G01968424Courtesy 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: Removing EGR Outlet Pipe From Lower Intake Manifold
    G01968425Courtesy of GENERAL MOTORS CORP.
  7. Remove the radiator inlet hose from the water outlet housing. Refer to RADIATOR HOSE REPLACEMENT - INLET (3.8L) in Engine Cooling.
    Fig 4: Removing Radiator Inlet Hose From Water Outlet Housing
    G01968426Courtesy of GENERAL MOTORS CORP.
  8. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
    Fig 5: Disconnecting Engine Coolant Temperature Sensor Electrical Connector
    G01968427Courtesy of GENERAL MOTORS CORP.
  9. Remove the generator brace bracket bolts.
    Fig 6: Removing Generator Brace Bracket & Bolts
    G01968428Courtesy of GENERAL MOTORS CORP.
  10. Remove the generator brace bracket.
  11. Remove the lower intake manifold bolts.
  12. Remove the lower intake manifold.
    Fig 7: Removing Lower Intake Manifold & Bolts
    G01968429Courtesy of GENERAL MOTORS CORP.
  13. Remove the lower intake manifold seals.
    Fig 8: Removing Lower Intake Manifold Seals
    G01968430Courtesy of GENERAL MOTORS CORP.
  14. Remove the lower intake manifold gaskets.
    Fig 9: Removing Lower Intake Manifold Gaskets
    G01968431Courtesy of GENERAL MOTORS CORP.
  15. If replacing the lower intake manifold, remove the water outlet housing bolt, stud and the water outlet housing.
    Fig 10: Removing Water Outlet Housing Bolt, Stud & Water Outlet Housing
    G01968432Courtesy of GENERAL MOTORS CORP.
  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.
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