GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Generic 🢒 2002 🢒 Unit Repair 🢒 Engine 🢒 Engine Mechanical - 5.0L and 5.7L 🢒 Intake Manifold Disassemble

    Object Number: 500661 Size: SH
  1. Remove the bolt, the nut, and the accelerator control cable bracket.

    2. Object Number: 500667 Size: SH
  2. Remove the throttle body attaching studs.
  3. Remove the throttle body.
  4. Remove the throttle body to upper intake manifold gasket.
  5. Discard the throttle body to upper intake manifold gasket.

    6. Object Number: 500671 Size: SH
  6. Remove the water outlet studs.
  7. Remove the water outlet.
  8. Remove the engine coolant thermostat.

    9. Object Number: 480563 Size: SH

    Important: Note the position and direction of the exhaust gas recirculation (EGR) valve before removal. It is possible to improperly install the EGR valve 180 degrees from the original position.

  9. Remove the exhaust gas recirculation (EGR) valve bolts.

    10. Object Number: 480565 Size: SH

    Notice: The Linear EGR valve is an electrical component. DO NOT soak in any liquid cleaner or solvent because damage may result.

  10. Remove the EGR valve and EGR valve gasket from the lower intake manifold.
  11. Discard the EGR valve gasket.

    12. Object Number: 10932 Size: SH
  12. Remove the engine coolant temperature (ECT) sensor from the lower intake manifold.

    13. Object Number: 500674 Size: SH
  13. Remove the studs and the ignition coil.

    14. Object Number: 500677 Size: SH
  14. Remove the manifold absolute pressure (MAP) sensor from the upper intake manifold.
  15. Remove the MAP sensor seal from the MAP sensor.
  16. Discard the MAP sensor seal.

    17. Object Number: 500679 Size: SH
  17. Remove the fuel pipe bolt (4).
  18. Remove the nuts (2) and the fuel pipe retainer (1).
  19. Remove the fuel pipe (3).
  20. Remove and discard the fuel seal retainers (5).
  21. Remove and discard the fuel seals (6) (yellow O-rings).
  22. Remove and discard the spacer rings (7) (flat washers).
  23. Remove and discard the fuel seals (8) (black O-rings).

    24. Object Number: 500680 Size: SH
  24. Remove the studs and the evaporative emission (EVAP) canister purge solenoid valve.
  25. Remove the nut and the engine wiring harness bracket.

    26. Object Number: 500681 Size: MH
  26. Remove the upper intake manifold studs (1).
  27. Remove the upper intake manifold (2).
  28. Remove the upper intake manifold to lower intake manifold gasket (3).
  29. Discard the upper intake manifold to lower intake manifold gasket (3).
  30. Remove the fuel meter body seal (4).
  31. Discard the fuel meter body seal (4).
  32. Remove the 8 poppet nozzles from the lower intake manifold bores.
  33. Remove the fuel meter body (5) from the lower intake manifold (6).