Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSCHEVROLET2001CHEVY EXPRESS G2500, VAN CARGO EXTENDED, 5.7 R, L31/KL8REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 255 (ENGINE PERFORMANCE SYSTEM REMOVAL & INSTALLATION)AIR INDUCTION SYSTEMSINTAKE MANIFOLDREMOVAL (2.2L)
2001 Chevrolet Chevy Express G2500, Van Cargo Extended, 5.7 R, L31/KL8
Removal (2.2L)
2001 Chevrolet Chevy Express G2500, Van Cargo Extended, 5.7 R, L31/KL8SECTION Removal (2.2L)
WARNING: This page is about a different car, the 2003 GMC Sonoma, 2003 GMC Jimmy, 2003 Chevrolet S10 Pickup, and 2003 Chevrolet Blazer. However, it is still accessible from the selected car via links, so may be relevant.
- Turn ignition off. Disconnect negative battery cable. Remove air cleaner outlet resonator mounting screw. Disconnect air cleaner outlet resonator clamp at throttle body. Remove air cleaner outlet duct from air cleaner outlet resonator.
- Disconnect power brake booster vacuum hose at throttle body. Disconnect crankcase vent hose clamp and crankcase vent hose from top of engine. Remove air cleaner outlet resonator. Loosen remaining air intake duct clamps. Remove air intake duct from top of fan shroud. Remove upper fan shroud retaining screws and upper fan shroud.
- Disconnect harness connectors from Idle Air Control (IAC) motor, Manifold Absolute Pressure (MAP) sensor, Throttle Position (TP) sensor and Engine Coolant Temperature (ECT) sensor. See Figure.
- Disconnect fuel injector harness connector. Remove fuel injector harness and engine wiring harness from bracket on valve cover and position aside. Disconnect vacuum hoses and EVAP purge tube from throttle body.
- Remove EVAP canister purge harness retaining bolt. On models equipped with A/T, remove transmission fluid fill tube retaining bolt. On all models, remove engine wiring harness clip-to-intake manifold retaining nuts.
- Disconnect fuel hose from the fuel rail. See FUEL LINE DISCONNECT FITTINGS under FUEL SYSTEMS. Disconnect control cables from throttle body.
- Reference mark spark plug wires at spark plugs for reassembly reference. Slightly twist all spark plug wires at spark plugs. Remove all spark plug wires at spark plugs by pulling on the wire boot. Remove spark plug wiring harness retainer from thermostat assembly and position wiring harness aside.
- Remove right-side fender wheelwell extension. See Figure. Working through wheelwell, remove rear generator brace. See Figure.
- Remove 2 engine wiring harness bracket-to-valve cover bolts. See Figure. Loosen engine wiring harness bracket-to-cylinder head bolt. Remove engine wiring harness bracket.
- Remove intake manifold bolts. See Figure. Remove intake manifold nuts. Remove fuel rail bracket. Remove intake manifold.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.