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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1721 (Engine Mechanical - 3.6L (5 Of 6)) >> Repair Instructions - Off Vehicle (3 Of 4) >> Intake Manifold Cleaning and Inspection (LY7) >> Inspection Procedure

Inspection 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: Front View Of Upper Intake Manifold
    GM1866909Courtesy of GENERAL MOTORS CORP.
  1. Inspect the upper intake manifold for the following conditions:
    • Damage, debris or restrictions to the BARO sensor mounting port
    • Damage, debris or restrictions to the brake vacuum booster hose port
    • Damage to the throttle body bolt holes
    • Damage, debris or restrictions to the PCV system hose ports
    2. Fig 2: Rear View Of Upper Intake Manifold
    GM1866910Courtesy of GENERAL MOTORS CORP.
  2. Inspect the upper intake manifold for the following conditions:
    • Damage to the intake manifold bolt bosses
    • Damage to the EVAP purge solenoid mounting boss
    • Damage, debris or restrictions to the EVAP purge solenoid port
    • Damage, debris or restrictions in the vacuum passage
    3. Fig 3: Intake Manifold Opening Cover Port
    GM1866912Courtesy of GENERAL MOTORS CORP.
  3. Inspect the upper intake manifold for the following conditions:
    • Damage, debris or restrictions to the intake manifold opening cover port (1)
    • Damage to the intake manifold opening cover
    4. Fig 4: Upper Intake Manifold Sealing Surfaces
    GM1866913Courtesy of GENERAL MOTORS CORP.
  4. Inspect the upper intake manifold for the following conditions:
    • Gouges or damage to the upper intake manifold sealing surfaces (1)
    • Damage to the gasket sealing surface (2) for the throttle body
    5. Fig 5: Inspecting Upper Intake Manifold Sealing Surface For Warpage
    GM1866914Courtesy of GENERAL MOTORS CORP.
  5. Inspect the upper intake manifold sealing surface for warpage.
    1. Locate a straight edge across the upper-to-lower intake manifold sealing surface.
    2. Insert a feeler gage between the upper intake manifold and the straight edge. An upper intake manifold with warpage in excess of 0.05 mm (0.020 in) must be replaced.
  6. Repair or replace the upper intake manifold as necessary.


    Fig 1: Lower Intake Manifold
    GM1866916Courtesy of GENERAL MOTORS CORP.
  1. Inspect the lower intake manifold for the following conditions:
    • Damage, debris or restrictions to the lower intake manifold ports
    • Damage to the fuel rail mounting bolt holes
    • Damage to the fuel rail
    2. Fig 2: Lower Intake Manifold
    GM1866918Courtesy of GENERAL MOTORS CORP.
  2. Inspect the lower intake manifold for the following conditions:
    • Gouges or damage to the intake manifold sealing surfaces
    • Damage to the lower intake manifold bolt bosses
    • Damage to the fuel injector ports
    3. Fig 3: Inspecting Lower Intake Manifold Sealing Surfaces For Warpage
    GM1866927Courtesy of GENERAL MOTORS CORP.
  3. Inspect the lower intake manifold sealing surfaces for warpage.
    1. Locate a straight edge across the lower intake manifold sealing surfaces.
    2. Insert a feeler gage between the lower intake manifold and the straight edge. A lower intake manifold with warpage in excess of 0.5 mm (0.020 in) must be replaced.
  4. Repair or replace the lower intake manifold as necessary.
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