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Home >> GMC >> 2006 >> Sierra 1500 HD, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 144 (Engine Mechanical - 4.3L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Intake Manifold Replacement - Lower >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2003 GMC Savana and 2003 Chevrolet Chevy Express. However, it is still accessible from the selected car via links, so may be relevant.

Important:  You do not have to remove the upper intake manifold in order to remove the lower intake manifold.

  1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure .
  2. Drain the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM .
  3. Remove the upper intake. Refer to Intake Manifold Replacement - Upper .
  4. Disconnect the A/C compressor (1) and the exhaust gas recirculation (EGR) connector (2).
  5. Remove the ground wire (4) from the stud at the water outlet.
    Fig 1: Disconnecting A/C Compressor & EGR Connectors & Removing Ground Wire
    G02077718Courtesy of GENERAL MOTORS CORP.
  6. Remove the radiator inlet hose at the water outlet. Refer to RADIATOR HOSE REPLACEMENT - INLET .
  7. Remove the heater hose from the intake manifold. Refer to HEATER HOSE REPLACEMENT - INLET and HEATER HOSE REPLACEMENT - OUTLET .
  8. Remove the water pump inlet hose from the intake manifold.
    Fig 2: Removing Water Pump Inlet Hose
    G02077719Courtesy of GENERAL MOTORS CORP.
  9. Remove the accelerator control cable bracket from the throttle body and the intake manifold.
  10. Remove the distributor. Refer to DISTRIBUTOR .
  11. Remove the spark plug wire harness retainer from the EGR valve inlet pipe.
    Fig 3: Removing Spark Plug Wire Harness Retainer
    G02077720Courtesy of GENERAL MOTORS CORP.
  12. In order to remove the front intake manifold bolt, perform the following:
    1. Remove the A/C compressor discharge hose from the vehicle. Refer to DISCHARGE HOSE REPLACEMENT .
    2. Remove the A/C compressor suction hose from the vehicle. Refer to SUCTION HOSE REPLACEMENT .
    3. Remove the drive belt. Refer to Drive Belt Replacement .
    4. Loosen the nut for the power steering pump rear bracket.
    5. Remove the bolts and the nut for the power steering pump mounting bracket.
    6. Leave the A/C compressor, if equipped, and the power steering pump on the bracket.
    7. Slide the power steering pump bracket forward to access the bolt at the front of the intake manifold.
      Fig 4: Removing Power Steering Pump Mounting Bracket
      G02077721Courtesy of GENERAL MOTORS CORP.
  13. Remove the engine coolant temperature (ECT) sensor wire connector, if equipped, from the engine wiring harness bracket.
  14. Remove the lower intake manifold bolts.

    Important:  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.

  15. Remove the intake manifold assembly.
  16. Remove and discard the lower intake manifold gaskets.
    17. Fig 5: Removing Bolts, Lower Intake Manifold Assembly & Gasket
    G02077722Courtesy of GENERAL MOTORS CORP.
  17. Clean all sealing surfaces and the intake manifold. Refer to Intake Manifold Cleaning and Inspection .
  18. If the intake manifold requires replacement refer to Intake Manifold Disassemble (LU3)  and Intake Manifold Assemble (LU3)  .
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