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Home >> Pontiac >> 2005 >> Grand Prix GXP >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 2 (Engine Mechanical - 3.8L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Intake Manifold Replacement - Lower (L32) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different variant/trim than selected.
    Fig 1: Radiator Inlet Hose
    GM405984Courtesy of GENERAL MOTORS CORP.
  1. Drain the cooling system. Refer to Draining and Filling Cooling System (L26 and L32) in Engine Cooling.
  2. Remove the supercharger. Refer to Supercharger Replacement .
  3. Remove the radiator inlet hose from the water outlet housing. Refer to Radiator Hose Replacement - Inlet (L26 L32) in Engine Cooling.
    4. Fig 2: EGR Outlet Pipe & Lower Intake Manifold
    GM911030Courtesy of GENERAL MOTORS CORP.
  4. Remove the exhaust gas recirculation (EGR) outlet pipe bolt (2) from the lower intake manifold.
  5. Remove the EGR outlet pipe (1) from the lower intake manifold.
  6. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
    7. Fig 3: Lower Intake Manifold, Bolts & Seals
    GM97724Courtesy of GENERAL MOTORS CORP.
  7. Remove the lower intake manifold bolts.
  8. Remove the lower intake manifold. The coolant bypass tube will release from the intake manifold as the manifold is removed.
  9. Remove the lower intake manifold seals.
  10. Remove the lower intake manifold gaskets.
  11. If replacing the lower intake manifold, remove the water outlet housing and the thermostat.
  12. If replacing the lower intake manifold, remove the ECT sensor.
  13. Inspect the flatness of the inlet flanges.
  14. Clean the lower intake manifold gasket mating surfaces.
  15. Clean the intake manifold bolts and the bolt holes of the adhesive compound.
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