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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 681 (Engine Mechanical - 8.1L (On-Vehicle)) >> Repair Instructions >> Intake Manifold Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2002 GMC Yukon XL, 2002 Chevrolet Suburban, and 2002 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.
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.
    Fig 1: View Of Air Cleaner Outlet Duct
    GM700979Courtesy of GENERAL MOTORS CORP.
  1. Loosen the clamps at the throttle body and air cleaner.
  2. Remove the air cleaner outlet duct.
    3. Fig 2: Intake Manifold Sight Shield, Bolts & Retainer
    GM665445Courtesy of GENERAL MOTORS CORP.
  3. Loosen the intake manifold sight shield bolt (3).
  4. Remove the sight shield from the bracket (1).
  5. Remove the sight shield bracket (1) and nuts.
  6. Relieve the fuel system pressure. Refer to FUEL SYSTEM PRESSURE RELEASE in Engine Controls - 8.1L.
  7. Disconnect the fuel feed and return lines. Refer to REMOVAL & INSTALLATION (METAL COLLAR) in Engine Controls - 8.1L.
    8. Fig 3: View Of MAF/IAT Sensor Electrical Connectors
    GM750582Courtesy of GENERAL MOTORS CORP.
  8. Disconnect the engine harness clips from the studs on the front of dash.
  9. Disconnect the engine harness clip from the wheelhouse splash panel.
  10. Disconnect the following electrical connectors:
    • Pressure cycling switch (1)
    • Surge tank switch (2)
    • Mass air flow (MAF) sensor (3)
  11. Reposition engine harness branch to top of engine.
    12. Fig 4: View Of Ignition Coil, ECT And MAP Sensor Electrical Connectors
    GM750529Courtesy of GENERAL MOTORS CORP.
  12. Remove the connector position assurance (CPA) retainer at the ignition coil harness.
  13. Disconnect the following electrical connectors:
    • Manifold absolute pressure (MAP) sensor (1)
    • Ignition coil harness (2)
    • Engine coolant temperature (ECT) sensor (3)
    14. Fig 5: Locating Engine Electrical Connectors
    GM750525Courtesy of GENERAL MOTORS CORP.
  14. Remove the engine harness bolt and studs.
  15. Remove the CPA retainer at the ignition coil harness.
  16. Disconnect the following electrical connectors:
    • Generator (1)
    • Injector harness (2)
    • Ignition coil harness (3)
    • Throttle position (TP) sensor (4)
    • Electronic throttle control (ETC) (5)
    • Purge valve solenoid (6)
  17. Reposition the engine harness to the drivers side of the engine compartment.
    18. Fig 6: Bypass Valve Vacuum Hose At Intake Manifold
    GM750614Courtesy of GENERAL MOTORS CORP.
  18. Remove the bypass valve vacuum hose (1) from the intake manifold.
    19. Fig 7: EGR Valve, Oil Pressure Sensor Electrical Connector & Engine Harness Ground Bolts & Straps
    GM750530Courtesy of GENERAL MOTORS CORP.
  19. Disconnect the exhaust gas recirculation (EGR) valve electrical connector (1).
    20. Fig 8: EGR Pipe, Bolts & Adapter
    GM635635Courtesy of GENERAL MOTORS CORP.
  20. Remove the EGR pipe bolts at the EGR adapter.
  21. Reposition the EGR pipe.
  22. Remove and discard the EGR valve pipe gasket.
    23. Fig 9: Fuel Pressure Regulator Vacuum Hose
    GM470770Courtesy of GENERAL MOTORS CORP.
  23. Remove the fuel pressure regulator vacuum hose.
    24. Fig 10: Fuel Rail & Studs
    GM470774Courtesy of GENERAL MOTORS CORP.
  24. If replacing the intake manifold, remove the fuel rail studs.
  25. Remove the fuel rail.
    26. Fig 11: Intake Manifold & Bolts
    GM470775Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Do not attempt to loosen the manifold by prying under the gasket surface with any tool.
  26. Remove the intake manifold bolts.
  27. Remove the intake manifold.
    28. Fig 12: Intake Manifold Gaskets
    GM470779Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The intake manifold gaskets are not reusable.
  28. Remove and discard the intake manifold side gaskets.
    29. Fig 13: Intake Manifold End Seals
    GM470783Courtesy of GENERAL MOTORS CORP.
  29. Remove and discard the intake manifold end seals.
    30. Fig 14: Intake Manifold Splash Shield
    GM470786Courtesy of GENERAL MOTORS CORP.
  30. Remove the splash shield.
  31. If replacing the intake manifold, refer to Intake Manifold Disassemble (C/K/C3500HD/Medium Duty) Intake Manifold Disassemble (G) in Engine Mechanical - 8.1L Unit Repair.
  32. Clean and inspect the intake manifold. Refer to Intake Manifold Cleaning and Inspection in Engine Mechanical - 8.1L Unit Repair.
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