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Removal (4.3L - Lower)

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NOTE: It is not necessary to remove the upper intake manifold in order to remove the lower intake manifold assembly.
NOTE: The following removal procedure is without the upper intake manifold removed. If it is necessary to remove or replace upper intake manifold, see REMOVAL (4.3L - UPPER INTAKE MANIFOLD) .
NOTE: Numbers in parenthesis refer to numbers in illustrations.
  1. Disconnect the battery negative cable. Remove the engine cover. Drain the cooling system. See COOLING SYSTEM BLEEDING  under COOLING SYSTEM.
  2. Remove the retaining nut from the air cleaner outlet. Remove the air cleaner outlet duct from the throttle body assembly. Disconnect the harness connector of the Intake Air Temperature (IAT) sensor.
  3. Disconnect the A/C compressor (1), the Exhaust Gas Recirculation (EGR) connector (2) and the ECT sensor (3). Remove the ground wire (4) from the stud at the water outlet. See Fig 1.
  4. Remove the radiator inlet hose at the water outlet. See Fig 2. Remove the heater hose from the intake manifold. Remove the water pump inlet hose from the intake manifold.
  5. Remove the accelerator control cable bracket from the throttle body and the intake manifold. See Figure.
  6. Remove the distributor. See DISTRIBUTOR  under IGNITION SYSTEMS. Remove the spark plug wire harness retainer from the EGR valve inlet valve.
  7. In order to remove the front intake manifold bolt, perform the following: Remove the auxiliary evaporator tube from the A/C compressor (if equipped). Remove the drive belt. Loosen the nut for the power steering pump rear bracket. Remove the bolts and the nut for the power steering pump mounting bracket. See Fig 3. Leave the A/C compressor (if equipped), and the power steering pump on the bracket. Slide the power steering pump bracket forward to access the bolt at the front of the intake manifold.
    8. WARNING: The intake manifold may be removed as an assembly. DO NOT remove the specific intake manifold components unless component service is required. DO NOT allow dirt or debris to enter the fuel system. Ensure that the ends of the fuel system are properly sealed. DO NOT disassemble the Central Sequential Fuel Injection (SFI) unit unless service is required.
  8. Remove the Engine Coolant Temperature (ECT) sensor wire connector (if equipped) from the engine wiring harness bracket. Remove the lower intake manifold bolts. Remove the intake manifold assembly. Remove and discard the lower intake manifold gaskets.
Fig 1: Disconnecting Appropriate Lower Intake Manifold Component Connectors (4.3L)
G00252071Courtesy of GENERAL MOTORS CORP.
Fig 2: Removing/Installing Radiator Inlet Hose (4.3L)
G00252072Courtesy of GENERAL MOTORS CORP.
Fig 3: Removing Power Steering Pump Mounting Bracket Fasteners (4.3L)
G00252073Courtesy of GENERAL MOTORS CORP.
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