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Home >> GMC >> 2006 >> Sierra 1500 HD, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1667 (Engine Mechanical - 4.8L, 5.3L, 6.0L, 6.2L - Repair Instructions - On Vehicle) >> Intake Manifold Replacement (Without AFM) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2010 GMC Sierra, 2010 Chevrolet Silverado, and 2010 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Engine Harness Retainer Nut & Electrical Connectors
    GM1696891Courtesy of GENERAL MOTORS CORP.
  1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement .
  2. Remove the generator. Refer to Generator Replacement (V6) or Generator Replacement (V8) or Generator Replacement (6.6L) .
  3. Remove the engine harness retainer nut (1).
  4. Remove the engine harness retainer from the stud and locator pin.
  5. Disconnect the engine harness electrical connector (2) from the evaporative emission (EVAP) canister purge solenoid.
  6. Disconnect the engine wiring harness electrical connector (4) from the manifold absolute pressure (MAP) sensor.
    7. Fig 2: View Of CPA Retainer, Electrical Connectors & Engine Harness Clips
    GM1696892Courtesy of GENERAL MOTORS CORP.
  7. Remove the connector position assurance (CPA) retainer (1).
  8. Disconnect the engine harness electrical connector (1) from the ignition coil harness electrical connector.
  9. Disconnect the engine harness electrical connectors (3) from the left side fuel injectors.
  10. Remove the engine harness clip (4) from the ignition coil bracket stud.
    11. Fig 3: View Of CPA Retainer, Engine Harness Electrical Connectors & Harness Clips
    GM1696893Courtesy of GENERAL MOTORS CORP.
  11. Remove the CPA retainer (2).
  12. Disconnect the engine harness electrical connector (1) from the ignition coil harness electrical connector.
  13. Disconnect the engine harness electrical connector (3) from the throttle actuator.
  14. Remove the engine harness clip (4) from the generator battery jumper cable.
  15. Remove the engine harness clip (6) from the ignition coil bracket stud.
  16. Disconnect the engine harness electrical connectors (7) from the right side fuel injectors.
    17. Fig 4: View Of Engine Wiring Harness, Clip, Bolt & Connector
    GM1696914Courtesy of GENERAL MOTORS CORP.
  17. Remove the engine harness clip (1) bolt (3).
  18. Disconnect the engine harness electrical connector (2) from the engine coolant temperature (ECT) sensor.
  19. Gather the engine harness branches and tie the harness up out of the way to the cowl panel.
    20. Fig 5: View Of Brake Booster Vacuum Hose & Booster Fitting
    GM1696916Courtesy of GENERAL MOTORS CORP.
  20. Reposition the brake booster vacuum hose clamp at the booster.
  21. Remove the brake booster vacuum hose from the booster fitting.
  22. Secure the brake booster vacuum hose to the intake manifold.
    23. Fig 6: View Of EVAP Canister Purge Tube & Quick Connect Fitting
    GM1696917Courtesy of GENERAL MOTORS CORP.
  23. Disconnect the EVAP canister purge tube (1) quick connect fitting from the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service .
  24. Disconnect the fuel feed line quick connect fitting (2) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
    25. Fig 7: View Of PCV Hose
    GM1696791Courtesy of GENERAL MOTORS CORP.
  25. Remove the positive crankcase ventilation (PCV) hose from the intake manifold fitting.
  26. Position the hose out of the way.
    27. Fig 8: Removing/Installing Intake Manifold Bolts
    GM1403311Courtesy of GENERAL MOTORS CORP.
  27. Loosen the intake manifold bolts (512).
    28. NOTE: The aid of an assistant may be helpful in holding the engine harness up out of the way so the upper intake manifold cover does not get caught against the engine harness.
  28. Remove the intake manifold (500).
  29. Cover the cylinder head passages in order to prevent dirt or debris from entering the passages.
    30. Fig 9: View Of Intake Manifold-To-Cylinder Head Gasket
    GM1277097Courtesy of GENERAL MOTORS CORP.
  30. Remove and discard the intake manifold gaskets (514).
    31. Fig 10: View Of Vacuum Brake Booster Hose
    GM1697051Courtesy of GENERAL MOTORS CORP.
  31. If replacing the intake manifold, perform the following steps, otherwise proceed to step 21 of the installation procedure.
  32. Place the intake manifold on a clean work surface.
  33. Reposition the brake booster vacuum hose clamp at the intake manifold.
  34. Remove the brake booster vacuum hose from the intake manifold nipple.
    35. Fig 11: View Of Upper Intake Manifold Cover & Nut
    GM1697057Courtesy of GENERAL MOTORS CORP.
  35. Remove the upper intake manifold cover nut.
  36. Remove the upper intake manifold cover.
    37. Fig 12: View Of MAP Sensor & Retainer
    GM1697060Courtesy of GENERAL MOTORS CORP.
  37. Remove the manifold absolute pressure (MAP) sensor retainer.
  38. Remove the MAP sensor.
    39. Fig 13: View Of EVAP Tube & Purge Solenoid
    GM1697062Courtesy of GENERAL MOTORS CORP.
  39. Disconnect the EVAP tube quick connect fitting at the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service .
  40. Disengage the retainer securing the EVAP canister purge solenoid to the fuel rail.
  41. Remove the EVAP tube and purge solenoid.
    42. Fig 14: View Of Throttle Body, Gasket & Bolts/Nuts
    GM1697064Courtesy of GENERAL MOTORS CORP.
  42. Remove the throttle body bolts/nuts.
  43. Remove the throttle body.
  44. Remove and discard the throttle body gasket.
    45. Fig 15: View Of Fuel Rail & Bolts
    GM1697066Courtesy of GENERAL MOTORS CORP.
  45. Remove the fuel rail bolts.
    46. NOTE: Lift evenly on both sides of the fuel rail until all injectors are removed from their bores.
  46. Remove the fuel rail.
  47. Remove and discard the fuel injector lower O-ring seals.
    48. Fig 16: View Of Brake Booster Vacuum Hose Nipple
    GM1697067Courtesy of GENERAL MOTORS CORP.
    NOTE: Evenly push in the RED collar in order to remove the nipple.
  48. Remove the brake booster vacuum hose nipple.
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