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Home >> Pontiac >> 2007 >> Grand Prix GXP >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 2 (Engine Mechanical - 3.8L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Upper Intake Manifold Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different variant/trim than selected.
    Fig 1: Brake Booster Hose & Vacuum Source Manifold
    GM910975Courtesy of GENERAL MOTORS CORP.
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (RPO LS4) or Battery Negative Cable Disconnection and Connection (RPOs L26/L32) in Engine Electrical.
  2. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (L26)  or Fuel Injector Sight Shield Replacement (L32) .
  3. Remove the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls - 3.8L.
  4. Drain the cooling system. Refer to Draining and Filling Cooling System (L26, L32 GE 47716 Fill) or Draining and Filling Cooling System (L26, L32 Static Fill) or Draining and Filling Cooling System (LS4 GE 47716 Fill) or Draining and Filling Cooling System (LS4 Static Fill) in Engine Cooling.
  5. Remove the right spark plug wires from the ignition control module and the upper intake manifold and reposition the wires. Refer to Spark Plug Wire Replacement in Engine Controls - 3.8L.
  6. Relieve the fuel pressure. Refer to Fuel Pressure Relief in Engine Controls - 3.8L.
  7. Remove the brake booster hose (1) from the vacuum source manifold (2).
  8. Disconnect the electrical connectors from the following:
    • Electronic throttle control (ETC)
    • EVAP purge solenoid
    • Manifold absolute pressure (MAP) sensor
    • Mass air flow (MAF) sensor
    9. Fig 2: EGR Valve Wiring Harness Heat Shield Nut & Bolt
    GM911071Courtesy of GENERAL MOTORS CORP.
  9. Remove the exhaust gas recirculation (EGR) valve wiring harness heat shield nut (1), bolt (2) and the EGR heat shield (3).
  10. Disconnect the EVAP purge solenoid pipe quick connect fitting. Refer to Plastic Collar Quick Connect Fitting Service in Engine Controls - 3.8L.
    11. Fig 3: Fuel Rail Assembly & Fuel Injectors
    GM910936Courtesy of GENERAL MOTORS CORP.
  11. Remove the fuel rail assembly nuts (2).
  12. Remove the fuel rail assembly (1) with the fuel injectors (3).
    13. Fig 4: Upper Intake Manifold Bolts & Studs
    GM910998Courtesy of GENERAL MOTORS CORP.
  13. Remove the upper intake manifold bolts (1,4) and the studs (2,3).
  14. Clean the upper intake manifold bolt threads.
  15. Remove the upper intake manifold.
    16. Fig 5: Upper-To-Lower Intake Manifold Carrier Gasket
    GM405818Courtesy of GENERAL MOTORS CORP.
  16. Remove the upper-to-lower intake manifold carrier gasket from the upper intake manifold.
  17. If the upper intake manifold is being replaced, remove the following:
    • Throttle body
    • Manifold absolute pressure (MAP) sensor
    • Positive crankcase ventilation (PCV) valve
    • Vacuum source manifold
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