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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 884 (Engine Mechanical - 2.2L (LN2)) >> Repair Instructions >> On-Vehicle Repair Instructions >> Intake Manifold Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2003 GMC Sonoma and 2003 Chevrolet S10 Pickup. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Battery.
  2. Remove the upper fan shroud. Refer to FAN SHROUD REPLACEMENT in Engine Cooling.
  3. Disconnect the power brake booster vacuum hose.
  4. Remove the air cleaner outlet resonator.
    Fig 1: Disconnecting Power Brake Booster Vacuum Hose
    G01976953Courtesy of GENERAL MOTORS CORP.
  5. Disconnect the following electrical connectors:
    • Idle air control (IAC) motor (1)
    • Manifold absolute pressure (MAP) sensor (4)
    • Throttle position (TP) sensor (2)
    • Engine coolant temperature (ECT) sensor (3)
      Fig 2: Disconnecting Electrical Connectors
      G01976954Courtesy of GENERAL MOTORS CORP.
  6. Disconnect the fuel injector harness electrical connector.
  7. Remove the fuel injector harness electrical connector from the bracket on the valve rocker arm cover.
  8. Remove the engine wiring harness from the bracket.
  9. Move and secure the engine wiring harness out of the way.
    Fig 3: Removing Engine Wiring Harness From Bracket
    G01976955Courtesy of GENERAL MOTORS CORP.
  10. Disconnect the heating and air conditioning control vacuum source hose.
  11. Disconnect the EVAP emission purge tube from the throttle body.
    Fig 4: Disconnecting EVAP Emission Purge Tube From Throttle Body
    G01976956Courtesy of GENERAL MOTORS CORP.
  12. Remove the bolt holding the EVAP emission canister purge harness and if equipped the transmission fluid fill tube.
  13. Remove the nut holding the engine wiring harness clip to the intake manifold.
  14. Remove the nut holding the engine wiring harness clip to the intake manifold rear lower stud.
  15. Disconnect the fuel hose from the fuel rail.
  16. Remove the accelerator control cable from the throttle body.
    Fig 5: Removing Nut Holding Engine Wiring Harness Clip To Intake Manifold
    G01976957Courtesy of GENERAL MOTORS CORP.
  17. Remove the cruise control cable from the throttle body. Refer to CRUISE CONTROL CABLE REPLACEMENT (2.2L) in Cruise Control.
  18. Remove the spark plug wires from the spark plugs. Refer to FIRING ORDER in Service & Adjustment Specifications - 2.2L in Engine Performance.
  19. Remove the spark plug wire harness retainer from the thermostat assembly and set aside the spark plug wire harness.
    Fig 6: Removing Spark Plug Wire Harness Retainer From Thermostat Assembly
    G01976958Courtesy of GENERAL MOTORS CORP.
  20. Remove the right fender wheelhouse extension.
    Fig 7: Removing Right Fender Wheelhouse Extension
    G01976959Courtesy of GENERAL MOTORS CORP.
  21. Working through the wheelhouse, remove the generator rear brace from the engine.
    • Remove the nuts holding the brace to the intake stud and the engine block.
    • Remove the bolt holding the brace to the rear of the generator.
      Fig 8: Removing Generator Rear Brace From Engine
      G01976960Courtesy of GENERAL MOTORS CORP.
  22. Remove the engine wiring harness bracket at the back of the engine using the following procedure:
    1. 22.1. Loosen the bolt at the rear of the cylinder head.
    2. 22.2. Remove the 2 bolts that secure the bracket to the valve rocker arm cover.
    3. 22.3. Slide the bracket off of the bolt at the rear of the cylinder head.
      Fig 9: Removing Engine Wiring Harness Bracket At Back Of Engine
      G01976961Courtesy of GENERAL MOTORS CORP.
  23. Remove the intake manifold bolts.
  24. Remove the intake manifold nuts.
  25. Remove the fuel rail bracket.
  26. Remove the intake manifold.
  27. If replacing the intake manifold remove the following:
    • The throttle body

    • The fuel rail

  28. Clean the intake manifold mating surfaces.
  29. Inspect the intake manifold for damage.
  30. Inspect the intake manifold for cracks near compression limiters.
    Fig 10: Removing Intake Manifold
    G01976962Courtesy of GENERAL MOTORS CORP.
  31. Inspect the crankcase ventilation passages in the intake manifold face for blockage and clean as necessary.
  32. Replace the intake manifold as necessary.
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