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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 406 (Engine Mechanical - 3.5L (On-Vehicle)) >> Repair Instructions >> Intake Manifold Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2002 Oldsmobile Aurora. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect the battery ground (negative) cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PRO in Electrical.
  2. Carefully disconnect the throttle body air inlet duct from the throttle body.
  3. Partially drain the engine coolant from the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
  4. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
    5. Fig 1: Removing Fuel Injector Sight Shield
    G01816670Courtesy of GENERAL MOTORS CORP.
  5. Disconnect the accelerator cable from the throttle body and accelerator cable bracket. Refer to THROTTLE BODY in Engine Controls-3.5L and CRUISE CONTROL CABLE (4.0L V8) or CRUISE CONTROL CABLE (3.5L V6) in Cruise Control.
  6. Disconnect the cruise control cable from the throttle body and accelerator cable bracket. Refer to CRUISE CONTROL CABLE (4.0L V8) or CRUISE CONTROL CABLE (3.5L V6) in Cruise Control.
  7. Disconnect the throttle body coolant hoses from the throttle body.
  8. Disconnect the fuel lines from the throttle body.
    Fig 2: Disconnecting Fuel Lines From Throttle Body
    G01816671Courtesy of GENERAL MOTORS CORP.
  9. Disconnect the fuel vapor line from the EVAP canister purge solenoid. Refer to EVAP CANISTER PURGE SOLENOID in Engine Controls-3.5L.
    Fig 3: Disconnecting Fuel Vapor Line From EVAP Canister Purge Solenoid
    G01816672Courtesy of GENERAL MOTORS CORP.
  10. Disconnect the brake booster vacuum hose from the brake booster.
    Fig 4: Disconnecting Brake Booster Vacuum Hose From Brake Booster
    G01816673Courtesy of GENERAL MOTORS CORP.
  11. Disconnect the A/C vacuum hose from the intake manifold.
  12. Disconnect the surge tank inlet pipe retainer from the fuel injector rail.
  13. Disconnect the fuel injector wiring harness connectors. Refer to COMPONENT LOCATIONS in Engine Controls-3.5L.
  14. Disconnect the engine wiring harness connectors from the following components:

    Refer to COMPONENT LOCATIONS in Engine Controls-3.5L.

    • Throttle position (TP) sensor
    • Idle air control (IAC) valve
    • EVAP canister purge solenoid
    • Manifold absolute pressure (MAP) sensor
    Fig 5: Identifying A/C Vacuum Hose
    G01816674Courtesy of GENERAL MOTORS CORP.
  15. Remove the engine wiring harness channel bolts from the camshaft covers.
  16. Remove and set aside the engine wiring harness and channel. Refer to COMPONENT LOCATIONS in Engine Controls-3.5L.
  17. Disconnect the fuel pressure regulator vacuum tube (1) from the regulator (2) and the throttle body (3).
    Fig 6: Disconnect Fuel Pressure Regulator Vacuum Tube From Regulator And Throttle Body
    G01816675Courtesy of GENERAL MOTORS CORP.
  18. Disconnect and remove both feed tubes (1, 2) from the camshaft covers and intake manifold.
    Fig 7: Removing Feed Tubes From Camshaft Covers & Intake Manifold
    G01816676Courtesy of GENERAL MOTORS CORP.

    Important:  The EGR valve outlet pipe incorporates a crush seal connection at the water crossover. The EGR valve outlet pipe must be replaced if disconnected from the water crossover.

  19. Remove the EGR valve outlet pipe bolts from the intake manifold and the water crossover.
  20. Remove the EGR outlet pipe and discard.
    Fig 8: Removing EGR Outlet Pipe
    G01816677Courtesy of GENERAL MOTORS CORP.
  21. Disconnect the 4 fuel rail snap-lock retainers by pushing toward the camshaft covers and lifting.
  22. Remove the fuel rail (1) and fuel injectors (2) as an assembly and store in a clean, secure location away from any heat sources.
    Fig 9: Removing Fuel Rail & Fuel Injectors
    G01816678Courtesy of GENERAL MOTORS CORP.
  23. Remove the intake manifold bolts.
    Fig 10: Removing Intake Manifold Bolts
    G01816679Courtesy of GENERAL MOTORS CORP.
  24. Disconnect the throttle body coolant hose from the water crossover feed tube (1).
    Fig 11: Disconnecting Throttle Body Coolant Hose From Water Crossover Feed Tube
    G01816680Courtesy of GENERAL MOTORS CORP.
  25. Remove the intake manifold.
  26. Clean and inspect intake manifold. Refer to INTAKE MANIFOLD CLEANING AND INSPECTION in Engine Mechanical-3.5L Unit Repair.
    Fig 12: Removing Intake Manifold
    G01816681Courtesy of GENERAL MOTORS CORP.
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