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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 356 (Engine Mechanical - 3.1L V6 - VIN (J) (On-Vehicle)) >> Repair Instructions >> Intake Manifold Replacement - Lower >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2002 Buick Century. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect the negative battery cable.
  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: Engine Coolant Temperature (ECT) Sensor Electrical Connector
    G01763549Courtesy of GENERAL MOTORS CORP.
  6. Disconnect and remove the fuel injector and the Manifold Absolute Pressure (MAP) sensor wiring harnesses.
    Fig 2: Fuel Injector And The Manifold Absolute Pressure (MAP) Sensor Wiring Harnesses
    G01763550Courtesy of GENERAL MOTORS CORP.
  7. Remove the fuel pipe clip bolt.
    Fig 3: Fuel Pipe Clip Bolt
    G01763551Courtesy of GENERAL MOTORS CORP.
  8. Remove the fuel pipe clip.
    Fig 4: Fuel Pipe Clip
    G01763552Courtesy of GENERAL MOTORS CORP.
  9. Remove the fuel feed pipe from the fuel injector rail. Refer to FUEL HOSE/PIPES REPLACEMENT - FILTER TO ENGINE in ENGINE CONTROLS - REMOVAL & INSTALLATION, OVERHAUL .
    Fig 5: Fuel Feed Pipe To The Fuel Injector Rail
    G01763553Courtesy of GENERAL MOTORS CORP.
  10. Remove the fuel return pipe from the fuel injector rail. FUEL HOSE/PIPES REPLACEMENT - FILTER TO ENGINE in ENGINE CONTROLS - REMOVAL & INSTALLATION, OVERHAUL .
    Fig 6: Fuel Return Pipe To The Fuel Injector Rail
    G01763554Courtesy of GENERAL MOTORS CORP.
  11. Remove the fuel injector rail. Refer to FUEL RAIL ASSEMBLY REPLACEMENT in ENGINE CONTROLS - REMOVAL & INSTALLATION, OVERHAUL .
    Fig 7: Fuel Injector Rail
    G01763555Courtesy 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) .
  13. Remove the heater inlet pipe with heater hose from the lower intake manifold and reposition.
  14. Remove the radiator inlet hose from the engine. Refer to RADIATOR HOSE REPLACEMENT - INLET (3.1L) in ENGINE COOLING SYSTEM .
    Fig 8: Radiator Inlet Hose To The Engine
    G01763556Courtesy of GENERAL MOTORS CORP.
  15. Remove the thermostat bypass hose from the thermostat bypass pipe and lower intake manifold pipe.
    Fig 9: Thermostat Bypass Hose To The Thermostat Bypass Pipe And Lower Intake Manifold Pipe
    G01763557Courtesy of GENERAL MOTORS CORP.
  16. Remove the lower intake manifold bolts.
  17. Remove the lower intake manifold.
  18. Remove the valve rocker arms and pushrods. Refer to Valve Rocker Arm and Push Rod Replacement .
    Fig 10: Valve Rocker Arms And Pushrods
    G01763558Courtesy of GENERAL MOTORS CORP.
  19. Remove the lower intake manifold gaskets and seals.
  20. Clean the lower intake manifold gasket mating surfaces.
  21. Remove and clean all the RTV sealant from the lower intake manifold and the engine block (1).
    Fig 11: Engine Block
    G01763559Courtesy of GENERAL MOTORS CORP.
  22. Remove the ECT sensor.
    Fig 12: ECT Sensor
    G01763560Courtesy of GENERAL MOTORS CORP.
  23. Remove the water outlet bolts.
  24. Remove the water outlet.
    Fig 13: Water Outlet And Bolts
    G01763561Courtesy of GENERAL MOTORS CORP.
  25. Remove the thermostat.
    Fig 14: Thermostat
    G01763562Courtesy of GENERAL MOTORS CORP.
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