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 G3500, VAN PASSENGER EXTENDED, 6.5 FREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 202 (ENGINE CONTROLS - REMOVAL & INSTALLATION)AIR INDUCTION SYSTEMSUPPER INTAKE MANIFOLD ASSEMBLYREMOVAL
2001 Chevrolet Chevy Express G3500, Van Passenger Extended, 6.5 F
Upper Intake Manifold Assembly: Removal
2001 Chevrolet Chevy Express G3500, Van Passenger Extended, 6.5 FSECTION Removal
WARNING: This page is about a different car, the 2003 GMC Safari and 2003 Chevrolet Astro. However, it is still accessible from the selected car via links, so may be relevant.
- Disconnect negative battery cable. Remove engine cover. SeeENGINE COVER under MISCELLANEOUS. Remove air cleaner outlet duct from throttle body. Disconnect accelerator control cable from throttle shaft and bracket. Disconnect cruise control cable from throttle shaft and bracket (if equipped).
- Remove PCV valve hose assembly from intake manifold and valve cover. See Figure . Remove nut retaining engine wiring harness bracket to intake manifold stud at left rear corner of engine. See Figure . Remove nut retaining A/C hose bracket to intake manifold stud (if equipped).
- Disconnect harness connectors from Throttle Position (TP) sensor (2), Idle Air Control (IAC) valve (3) and fuel meter body assembly (4). Disconnect A/C compressor clutch (1) and A/C high pressure cut-off switch (5) harness connectors (if equipped). See Figure .
- Disconnect Manifold Absolute Pressure (MAP) sensor (4), ignition coil (2) and EVAP canister purge solenoid valve (1) harness connectors. See Figure . Remove nut retaining engine wiring harness bracket to intake manifold stud near EVAP canister purge solenoid valve on right side of engine. See Figure . Secure engine wiring harness aside.
- Disconnect EVAP canister purge solenoid valve pipe at the EVAP canister purge solenoid valve and secure aside. Label and disconnect remaining vacuum hose(s) for installation reference. Remove transmission fluid filler tube-to-accelerator control cable bracket retaining bolt. Remove accelerator control cable bracket from throttle body and intake manifold.
- Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE under FUEL SYSTEMS. Disconnect fuel lines at fuel meter body assembly. Remove upper intake manifold retaining studs and upper intake manifold.
RENDER: 1.0x
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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.