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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 834 (Engine Mechanical - 4.8L, 5.3L & 6.0L) >> Repair Instructions >> 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 a complete assembly. If not servicing the individual components, remove the manifold as a complete assembly.

  1. Remove the throttle body. Refer to THROTTLE BODY in Engine Controls - 4.8L, 5.3L, and 6.0L.
  2. Remove the fuel injectors. Refer to FUEL RAIL ASSEMBLY in Engine Controls - 4.8L, 5.3L, and 6.0L.
  3. Disconnect the following electrical connectors:
    • The manifold absolute pressure (MAP) sensor (1)
    • The knock sensor (2)
    Fig 1: Disconnecting MAP Sensor & Knock Sensor
    G02116334Courtesy of GENERAL MOTORS CORP.
  4. Remove the knock sensor harness electrical connector from the intake manifold.
  5. Set the electrical harness aside.
  6. If equipped with vacuum assisted brakes, remove the vacuum brake booster hose from the rear of the intake manifold.
    Fig 2: Removing Knock Sensor Harness Electrical Connector From Intake Manifold
    G02116335Courtesy of GENERAL MOTORS CORP.
  7. Remove the positive crankcase ventilation (PCV) hose with valve.
    Fig 3: Removing PCV Hose With Valve
    G02116336Courtesy of GENERAL MOTORS CORP.
  8. Remove the MAP sensor (1) from the intake manifold.
    Fig 4: Removing MAP Sensor From Intake Manifold
    G02116337Courtesy of GENERAL MOTORS CORP.
  9. Remove the evaporative emission (EVAP) purge solenoid vent tube by performing the following:
    1. 9.1. Remove the EVAP tube end from the solenoid (1).
    2. 9.2. Remove the EVAP tube end from the vapor pipe (2).
    Fig 5: Removing EVAP Tube End From Solenoid
    G02116338Courtesy of GENERAL MOTORS CORP.
  10. Remove the EVAP purge solenoid bolt (2), solenoid (3), and isolator (1) from the intake manifold.
    Fig 6: Removing EVAP Purge Solenoid Bolt, Solenoid & Isolator From Intake Manifold
    G02116339Courtesy of GENERAL MOTORS CORP.
  11. Loosen the intake manifold bolts.
  12. Remove the intake manifold.
    Fig 7: Removing Intake Manifold
    G02116340Courtesy of GENERAL MOTORS CORP.
  13. Remove the intake manifold gaskets (1) from the intake manifold.
  14. Discard the old intake manifold gaskets.
  15. If required, clean and inspect the intake manifold. Refer to Intake Manifold Cleaning and Inspection  .
    Fig 8: Removing Intake Manifold Gaskets From Intake Manifold
    G02116341Courtesy of GENERAL MOTORS CORP.
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