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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1634 (Engine Mechanical - 3.5L) >> Repair Instructions - On Vehicle >> Upper Intake Manifold Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2009 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of PCV Tube & Air Inlet Duct
    GM1608799Courtesy of GENERAL MOTORS CORP.
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  2. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .
  3. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill Without HP5)Cooling System Draining and Filling (GE 47716 Fill Without HP5) .
  4. Remove the positive crankcase ventilation (PCV) fresh air tube. Refer to Plastic Collar Quick Connect Fitting Service .
    5. Fig 2: Locating PCV Foul Air Tube
    GM1608801Courtesy of GENERAL MOTORS CORP.
  5. Remove the PCV foul air tube. Refer to Plastic Collar Quick Connect Fitting Service .
    6. Fig 3: View Of Brake Booster Vacuum Hose & Intake Manifold
    GM1608820Courtesy of GENERAL MOTORS CORP.
  6. Remove the vacuum hose from the intake manifold.
    7. Fig 4: Coolant Inlet And Outlet Hoses/Pipes
    GM1608325Courtesy of GENERAL MOTORS CORP.
  7. Reposition the heater inlet and outlet hose/pipe clamps at the engine pipes.
  8. Remove the heater inlet and outlet hose/pipe clamp nuts from the throttle body studs.
  9. Remove the heater inlet and outlet hoses/pipes from the engine pipes and the throttle body studs.
  10. Reposition the hoses/pipes out of the way.
    11. Fig 5: View Of MAP Sensor Electrical Connector
    GM1608869Courtesy of GENERAL MOTORS CORP.
  11. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (1).
    12. Fig 6: View Of EVAP Canister Purge Solenoid Electrical Connector
    GM1608290Courtesy of GENERAL MOTORS CORP.
  12. Disconnect the evaporative emission (EVAP) canister purge solenoid electrical connector (1).
  13. Disconnect the chassis EVAP line quick connect fitting from the purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service .
  14. Disconnect the electronic throttle control (ETC) electrical connector (2).
    15. Fig 7: View Of Left Side Spark Plug Wires
    GM1608802Courtesy of GENERAL MOTORS CORP.
  15. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  16. Disconnect the left side spark plug wires from the spark plugs.
  17. Disconnect the left side spark plug wires from the ignition coil.
  18. Disengage the spark plug wire retainer clips from the intake manifold bracket and the heater inlet/outlet hose/pipe bracket.
  19. Remove the left side spark plug wires.
    20. Fig 8: Identifying Throttle Body, Throttle Body Seal & Intake Manifold
    GM1608805Courtesy of GENERAL MOTORS CORP.
  20. Remove the throttle body bolts and nuts.
  21. Remove the throttle body and gasket.
    22. Fig 9: View Of MAP Sensor Seal & Upper Intake Manifold
    GM1608814Courtesy of GENERAL MOTORS CORP.
  22. Remove the MAP sensor bracket bolts.
  23. Remove the MAP sensor bracket and sensor.
    24. Fig 10: View Of Upper Intake Manifold & Lower Intake Manifold
    GM1608816Courtesy of GENERAL MOTORS CORP.
  24. Remove the ignition coil bracket (to intake manifold) bolts.
  25. Remove the intake manifold cover ball stud nut from the intake manifold stud.
  26. Remove the upper intake manifold bolts and stud.
  27. Separate and remove the upper intake manifold from the lower intake manifold.
  28. Remove the upper to lower intake manifold gaskets.
  29. Clean the upper intake to lower intake gasket mating surfaces.
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