Removal Procedure

Important:  The intake manifold, throttle body, fuel injection rail, and injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.

1. Drain the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
2. If replacing the intake manifold, perform the following:
   • Remove the throttle body. Refer to THROTTLE BODY .
   • Remove the fuel injectors. Refer to FUEL RAIL & INJECTORS .
3. Remove the right fuel rail cover.
   Fig 1: Removing Right Fuel Rail Cover

   Courtesy of GENERAL MOTORS CORP.
4. Remove the left fuel rail cover.
   Fig 2: Removing Left Fuel Rail Cover

   Courtesy of GENERAL MOTORS CORP.
5. Remove the fuel feed hose. Refer to REMOVAL (QUICK-CONNECT FITTING -- WITH METAL COLLAR .
   Fig 3: Removing Fuel Feed Hose

   Courtesy of GENERAL MOTORS CORP.
6. Disconnect the evaporative emission (EVAP) canister purge tube from the intake manifold.
7. Disconnect the EVAP canister purge tube from the EVAP canister purge solenoid valve.
8. Remove the EVAP canister purge tube.
9. Disconnect the EVAP canister purge tube from the EVAP canister purge solenoid valve.
10. Disconnect the EVAP canister purge tube from the fuel feed pipe.
11. Remove the EVAP canister purge tube.
    Fig 4: Disconnecting EVAP Canister Purge Tube

    Courtesy of GENERAL MOTORS CORP.
12. Disconnect the throttle position (TP) sensor electrical connector.
    Fig 5: Disconnecting Throttle Position (TP) Sensor Electrical Connector

    Courtesy of GENERAL MOTORS CORP.
13. Remove the coolant air bleed hose. Refer to COOLANT AIR BLEED HOSE REPLACEMENT in Engine Cooling.
14. Reposition the throttle body heater outlet hose clamp at the throttle body.
15. Remove the throttle body heater outlet hose from the throttle body.
16. Remove the throttle body heater outlet hose.
    Fig 6: Removing Throttle Body Heater Outlet Hose

    Courtesy of GENERAL MOTORS CORP.
17. Disconnect all the fuel injector electrical connectors (1).
    Fig 7: Disconnecting Electrical Connectors

    Courtesy of GENERAL MOTORS CORP.
18. Disconnect the EVAP canister purge solenoid valve electrical connector (2).
19. Disconnect the electronic throttle control (ETC) electrical connector (3).
20. Remove the EVAP canister purge solenoid valve from the bracket.
    Fig 8: Removing EVAP Canister Purge Solenoid Valve

    Courtesy of GENERAL MOTORS CORP.
21. Disconnect the harness clips at the fuel rails.
22. Reposition the intake manifold branches of the wiring harness.
23. Disconnect the power brake booster vacuum hose at the booster.
    Fig 9: Disconnecting Power Brake Booster Vacuum Hose

    Courtesy of GENERAL MOTORS CORP.
24. Remove the knock sensor wire harness (1) clip from the fuel rail stop bracket (2).
    Fig 10: Removing Knock Sensor Wire Harness Clip

    Courtesy of GENERAL MOTORS CORP.
25. Remove the TP sensor harness clip from the positive crankcase ventilation (PCV) tube.
26. Remove the PCV tube from the right rocker arm cover and throttle body.
    Fig 11: Removing TP Sensor Harness Clip From Positive Crankcase Ventilation (PCV) Tube

    Courtesy of GENERAL MOTORS CORP.
27. If equipped with the regular production option (RPO) LS1 engine, remove the PCV valve pipe from the left rocker arm cover.
    Fig 12: Removing PCV Valve Pipe From Left Rocker Arm Cover

    Courtesy of GENERAL MOTORS CORP.
28. If equipped with the RPO LS1 engine, remove the PCV valve pipe strap nut.
29. Remove the PCV valve pipe from the right rocker arm cover and intake manifold.
    Fig 13: Removing PCV Valve Pipe From Right Rocker Arm Cover And Intake Manifold

    Courtesy of GENERAL MOTORS CORP.
30. If equipped with the RPO LS6 engine, remove the PCV valve hose (1) from the valley cover and intake manifold.
    Fig 14: Removing PCV Valve Hose

    Courtesy of GENERAL MOTORS CORP.
31. Remove the intake manifold bolts (1) and fuel rail stop bracket (2).
    Fig 15: Removing Intake Manifold Bolts And Fuel Rail Stop Bracket

    Courtesy of GENERAL MOTORS CORP.
32. Position the intake manifold forward.
33. Disconnect the manifold absolute pressure (MAP) sensor vacuum hose.
34. Disconnect the MAP sensor (3) electrical connector.
    Fig 16: Disconnecting MAP Sensor Electrical Connector

    Courtesy of GENERAL MOTORS CORP.
35. Remove the intake manifold.
    Fig 17: Removing Intake Manifold

    Courtesy of GENERAL MOTORS CORP.
36. Remove the intake manifold gaskets (1). Discard the old gaskets.
    Fig 18: Removing Intake Manifold Gaskets

    Courtesy of GENERAL MOTORS CORP.
37. Clean and inspect the intake manifold. Refer to INTAKE MANIFOLD CLEANING AND INSPECTION .