How To Change Intake Manifold In A 2003 Chevy

Do you need to know how to change the air intake manifold in a 2003 Chevy? Whether you are upgrading your car or the intake manifold in your Chevy needs replacing, here is a guide of how to change, remove and replace one. It is important to clamp the fuel line or disconnect the fuel pump relay. Start the engine until it dies from lack of fuel and pump out any fuel from the fuel lines.

Things you'll need:

  • Wrench set
  • Screwdriver
  • Clamp
  1. Remove the air filter and filter pipework from the intake manifold. Disconnect the throttle cable (and cruise control cable, if fitted). Disconnect all of the wiring and sensors that go to the intake manifold, working your way around it until the intake manifold is free from wiring. You can label each wire so you know where they go when you refit them.
  2. Set aside the EGR valve after disconnecting it. Remove the vacuum hoses and lines heading to the intake manifold. You can then start to loosen the bolts holding the intake to the cylinder head. Start at the middle bolts, loosening them half a turn at a time, working you way outwards, alternating from top to bottom bolts. Stuff the intake channels with paper to stop any dirt falling into the combustion chamber in the cylinder head.
  3. Disconnect the fuel line that comes from the fuel rail. Fuel may still be in the pipes, so it is handy to have a cloth ready to catch any drips. Remove the intake manifold and refit a new one, remembering to attach the bolts in an orderly fashion from inside to the outer edge and to use a new gasket set. Some high temperature sealant needs to be used on the gasket to ensure a good fit.
  4. Double check all of the sensors, wiring and pipework is refitted and un-clamp the fuel line. Start the engine and check that everything runs OK. It might take a few tries to get the fuel running through to the fuel rail. It is wise to flush the coolant at this point to save any air locks from occurring in the cooling system.
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