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HOMESERVICE MANUALSCHEVROLET2001SUBURBAN C1500REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 17 (ENGINE MECHANICAL - 4.3L - SERVICE, REPAIR AND DIAGNOSTICS)REPAIR INSTRUCTIONSLOWER INTAKE MANIFOLD REPLACEMENTREMOVAL PROCEDURE
2001 Chevrolet Suburban C1500

Removal Procedure

2001 Chevrolet Suburban C1500SECTION Removal Procedure
WARNING: This page is about a different car, the 2001 GMC Sierra and 2001 Chevrolet Silverado. However, it is still accessible from the selected car via links, so may be relevant.
IMPORTANT:

You do not have to remove the upper intake manifold in order to remove the lower intake manifold.

  1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Auxiliary Battery) , Battery Negative Cable Disconnection and Connection (Single Battery) in Engine Electrical.
  2. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
    3. Fig 1: View Of Air Cleaner Outlet Duct Clamp
    GM360851Courtesy of GENERAL MOTORS COMPANY
  3. Separate the MAF/IAT sensor assembly and the air inlet tube by loosening the hose clamp.
  4. Disconnect the PCV hose from the air cleaner outlet duct.
    5. Fig 2: View Of Air Cleaner Adapter Nut
    GM489179Courtesy of GENERAL MOTORS COMPANY
  5. Remove the air inlet tube and resonator retaining wing nut.
    6. Fig 3: View Of Air Cleaner Outlet Duct
    GM489176Courtesy of GENERAL MOTORS COMPANY
  6. Remove the air inlet tube and resonator from the throttle body by pivoting the air inlet tube and resonator upward until the hinge clip releases from the lip on the throttle body.
    7. Fig 4: Accelerator Cable Routing Bracket
    GM26764Courtesy of GENERAL MOTORS COMPANY
  7. Remove the accelerator cable from the cable routing bracket.
    8. Fig 5: Identifying Accelerator Cable/Throttle Body Lever
    GM325556Courtesy of GENERAL MOTORS COMPANY
  8. Remove the accelerator cable from the throttle body lever.
  9. Disconnect the cruise control cable, if equipped from the throttle shaft and the accelerator cable bracket at the side of the throttle body. Refer to Cruise Control Cable Replacement (V6) in Cruise Control.
    10. Fig 6: View Of Accelerator Control Cable Bracket
    GM398030Courtesy of GENERAL MOTORS COMPANY
  10. Remove the engine wiring harness and clip from the accelerator control cable bracket.
  11. Remove the accelerator control cable bracket with the accelerator control cable and the cruise control cable from the throttle body.
  12. Move and secure the accelerator control cable bracket with the cables out of the way.
    13. Fig 7: Secondary Air Injection (AIR) Crossover Pipe
    GM398868Courtesy of GENERAL MOTORS COMPANY
  13. Disconnect the secondary air injection (AIR) crossover pipe from the AIR pipe assemblies, if equipped.
  14. Remove the AIR crossover pipe, if equipped.
    15. Fig 8: Manifold Absolute Pressure (MAP) Sensor Connector And EVAP Canister Purge Solenoid Valve Connector
    GM491816Courtesy of GENERAL MOTORS COMPANY
  15. Disconnect the following electrical connectors:
    • The EVAP canister purge solenoid valve (1)
    • The manifold absolute pressure (MAP) sensor (2)
    • The ignition control module (ICM) (4)
    • The ignition coil (3)
    16. Fig 9: EGR Valve Connector, A/C Compressor Clutch Connector And A/C Pressure Switch Connector
    GM491821Courtesy of GENERAL MOTORS COMPANY
  16. Disconnect the following electrical connectors:
    • The A/C pressure switch (4), if equipped
    • The A/C compressor clutch (1), if equipped
    • The exhaust gas recirculation (EGR) valve (2)
    • The generator battery positive cable (3)
    17. Fig 10: Throttle Position (TP) sensor Connector, Idle Air Control (IAC) Motor Connector And Fuel Meter Body Assembly Connector
    GM491817Courtesy of GENERAL MOTORS COMPANY
  17. Disconnect the following electrical connectors:
    • The fuel meter body assembly (3)
    • The throttle position (TP) sensor (1)
    • The idle air control (IAC) motor (2)
    • The engine coolant temperature (ECT) sensor (4)
    18. Fig 11: Engine Wiring Harness Retainer Nuts
    GM310243Courtesy of GENERAL MOTORS COMPANY
  18. Remove the nut holding the engine wiring harness bracket to the EVAP purge solenoid valve stud.
  19. Remove the nut holding the ground wire to the engine wiring harness bracket stud at the rear of the right cylinder head.
  20. Remove the stud holding the engine wiring harness bracket.
    21. Fig 12: View Of Engine Wiring Harness Bracket & Nuts
    GM310241Courtesy of GENERAL MOTORS COMPANY
  21. Remove the two nuts holding the engine wiring harness bracket to the upper intake manifold studs.
  22. Remove the engine wiring harness bracket from the studs.
  23. Move the engine wiring harness with the brackets aside.
    24. Fig 13: View Of Radiator Inlet Hose, Clamps & Thermostat Housing
    GM367002Courtesy of GENERAL MOTORS COMPANY
  24. Remove the radiator inlet hose from the thermostat housing.
    25. Fig 14: View Of Water Pump Inlet Hose & Clamps
    GM182853Courtesy of GENERAL MOTORS COMPANY
  25. Remove the water pump inlet hose from the intake manifold.
  26. Remove the heater hoses from the engine. Refer to Heater Inlet Hose Replacement (L35) and Heater Outlet Hose Replacement (L35) in Heating Ventilation and Air Conditioning.
  27. Remove the distributor. Refer to Distributor Replacement in Engine Controls - 4.3L.
  28. Disconnect the fuel supply and return pipes at the rear of the intake manifold. Refer to Fuel Line Replacement - Engine in Engine Controls - 4.3L.
    29. Fig 15: Identifying Breather Tube
    GM172995Courtesy of GENERAL MOTORS COMPANY
  29. Disconnect PCV valve hose assembly from the intake manifold and the valve rocker arm cover.
    30. Fig 16: View Of Vacuum Brake Booster Hose
    GM346148Courtesy of GENERAL MOTORS COMPANY
  30. Disconnect the power brake booster vacuum hose from the intake manifold.
  31. Disconnect the hose to the EVAP canister purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement in Engine Controls - 4.3L.
    32. Fig 17: Spark Plug Wire Harness Retainer From Exhaust Gas Recirculation (EGR) Valve Inlet Pipe
    GM172982Courtesy of GENERAL MOTORS COMPANY
  32. Remove the spark plug wire harness retainer from the exhaust gas recirculation (EGR) valve inlet pipe.
  33. Remove the clamp bolt for the EGR valve inlet pipe.
  34. Remove the EGR valve inlet pipe from the intake and the exhaust manifolds.
    35. Fig 18: View Of Power Steering Pump Bracket
    GM340090Courtesy of GENERAL MOTORS COMPANY
  35. In order to remove the front intake manifold bolt, perform the following:
    1. Remove the drive belt. Refer to Drive Belt Replacement .
    2. Loosen the power steering pump rear bracket side nut.
    3. Remove the power steering pump rear bracket front nut.
    4. Remove the bolts and the nut for the power steering pump mounting bracket.
    5. Leave the A/C compressor, if equipped, and the power steering pump on the bracket.
    6. Slide the power steering pump mounting bracket forward to access the bolt at the front of the intake manifold.
    36. Fig 19: View Of Intake Manifold Assembly & Bolts
    GM31510Courtesy of GENERAL MOTORS COMPANY
  36. Remove the engine coolant temperature (ECT) sensor wire connector (if equipped) from the engine wiring harness bracket.
  37. Remove the lower intake manifold bolts.
    38. IMPORTANT:

    The intake manifold may be removed as an assembly. Do not remove the specific intake manifold components unless component service is required.

    Do not allow dirt or debris to enter the fuel system. Ensure that the ends of the fuel system are properly sealed.

    Do not disassemble the Central Sequential Fuel Injection (SFI) unit, unless service is required.

  38. Remove the intake manifold assembly.
  39. Remove and discard the lower intake manifold gaskets.
    40. IMPORTANT:

    Do not immerse the assembled intake manifold in cleaning solvent.

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.