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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 421 (Engine Mechanical - 4.8L, 5.3L, & 6.0L (On-Vehicle)) >> Repair Instructions >> Intake Manifold Replacement >> Removal Procedure

Removal Procedure

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    IMPORTANT: The intake manifold, throttle body, fuel rail, and injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.
  1. Remove the throttle body. Refer to THROTTLE BODY .
  2. Remove the fuel injectors. Refer to FUEL INJECTORS .
    3. Fig 1: View Of MAP Sensor & Knock Sensor Electrical Connectors
    GM679510Courtesy of GENERAL MOTORS CORP.
  3. Disconnect the following electrical connectors:
    • Manifold absolute pressure (MAP) sensor (1)
    • Knock sensor (2)
    • Exhaust gas recirculation (EGR) valve, if equipped.
  4. Remove the knock sensor harness electrical connector from the intake manifold.
  5. Set the electrical harness aside.
    6. Fig 2: MAP Sensor, Knock Sensor & EGR Valve
    GM679527Courtesy of GENERAL MOTORS CORP.
  6. If equipped, remove the following EGR pipe bolts:
    • Intake manifold (1)
    • Cylinder head (2)
    • Exhaust manifold (3)
  7. If equipped, remove the EGR pipe with valve.
  8. If equipped, remove the EGR pipe gasket from the exhaust manifold.
    9. Fig 3: Vacuum Brake Booster Hose At Intake Manifold Rear
    GM382483Courtesy of GENERAL MOTORS CORP.
  9. If equipped with vacuum assisted brakes, remove the vacuum brake booster hose from the rear of the intake manifold.
    10. Fig 4: Breather Crossover Tube View
    GM647793Courtesy of GENERAL MOTORS CORP.
  10. Remove the positive crankcase ventilation (PCV) hose with valve.
    11. Fig 5: MAP Sensor
    GM260159Courtesy of GENERAL MOTORS CORP.
  11. Remove the MAP sensor (1) from the intake manifold.
    12. Fig 6: Accelerator Control Cable Bracket & Bolts
    GM492765Courtesy of GENERAL MOTORS CORP.
  12. Remove the accelerator control cable bracket bolts (1).
  13. Remove the accelerator control cable bracket (2) from the intake manifold.
    14. Fig 7: View Of EVAP Purge Solenoid Vent Tube
    GM372717Courtesy of GENERAL MOTORS CORP.
  14. Remove the evaporative emission (EVAP) purge solenoid vent tube by performing the following:
    1. Remove the EVAP tube end (2) from the solenoid (1).
    2. Squeeze the EVAP pipe quick connect fitting (3) retainer together.
    3. Remove the EVAP tube end (3) from the vapor pipe.
    15. Fig 8: View Of EVAP Purge Solenoid Bolt, Solenoid & Isolator
    GM389993Courtesy of GENERAL MOTORS CORP.
  15. Remove the EVAP purge solenoid bolt (2), solenoid (3), and isolator (1) from the intake manifold.
    16. Fig 9: Intake Manifold & Bolts
    GM642285Courtesy of GENERAL MOTORS CORP.
  16. Remove the intake manifold bolts.
  17. Remove the intake manifold.
    18. Fig 10: View Of Intake Manifold Gasket
    GM492770Courtesy of GENERAL MOTORS CORP.
  18. Remove the intake manifold gaskets (1) from the intake manifold.
  19. Discard the old intake manifold gaskets.
  20. Clean and inspect the intake manifold. Refer to Intake Manifold Cleaning and Inspection in the Engine Mechanical - 4.8L, 5.3L, and 6.0L Unit Repair.
  21. If equipped with EGR, clean the gasket surfaces of the EGR pipe and the exhaust manifold.
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