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

Installation Procedure

2001 Chevrolet Suburban C1500SECTION Installation 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.
    Fig 1: Locating PCV Valve Cover
    GM516804Courtesy of GENERAL MOTORS COMPANY
  1. Install the throttle body, if removed. Refer to Throttle Body Assembly Replacement in Engine Controls - 4.3L.
  2. Install the MAP sensor, if removed. Refer to Manifold Absolute Pressure Sensor Replacement in Engine Controls - 4.3L.
  3. Install the PCV valve cover, if removed, using the following procedure:
    1. Install a NEW seal (O-ring) on the PCV valve cover.
    2. Lubricate the seal with clean engine oil.
    3. Install the PCV valve cover in the upper intake manifold.
    4. Turn and lock the PCV valve cover in position.
    4. Fig 2: Power Brake Booster Vacuum Fitting
    GM516797Courtesy of GENERAL MOTORS COMPANY
  4. Install the power brake booster vacuum tube fitting, if removed, using the following procedure:
    1. Install a NEW seal (O-ring) on the power brake booster vacuum tube fitting.
    2. Lubricate the seal with clean engine oil.
    3. Install the power brake booster vacuum tube fitting in the upper intake manifold.
    4. Turn and lock the power brake booster vacuum tube fitting in position.
    5. Fig 3: Fuel Meter Body O-Ring Seal
    GM516773Courtesy of GENERAL MOTORS COMPANY
  5. Install a NEW seal on the fuel meter body assembly.
  6. Lubricate the seal with clean engine oil.
    7. Fig 4: Intake Manifold Upper Gasket
    GM516790Courtesy of GENERAL MOTORS COMPANY
  7. Install a NEW upper intake manifold to lower intake manifold gasket in the groove of the upper intake manifold.
    8. Fig 5: Upper Intake Manifold
    GM516794Courtesy of GENERAL MOTORS COMPANY
  8. Install the upper intake manifold onto the lower intake manifold.
  9. If reusing the fasteners, apply threadlock GM P/N 12345382 or equivalent to the threads of the upper intake manifold attaching bolts.
  10. Refer to FASTENER NOTICE in Cautions and Notices.

    Install the upper intake manifold attaching studs.

    Tighten 

    1. Tighten the upper intake manifold attaching studs on the first pass to 5 N.m (44 lb in).
    2. Tighten the upper intake manifold attaching studs on the final pass to 9 N.m (80 lb in).
  11. Install the fuel lines to the fuel meter body assembly. Refer to Fuel Line Replacement - Engine in Engine Controls - 4.3L.
  12. Install the EVAP canister purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement in Engine Controls - 4.3L.
    13. Fig 6: Accelerator Control Cable Bracket
    GM398033Courtesy of GENERAL MOTORS COMPANY
  13. Install the accelerator control cable bracket to the throttle body and the intake manifold.

    Tighten 

    Tighten the accelerator control cable bracket studs and nuts to 12 N.m (106 lb in).

    14. Fig 7: Identifying Breather Tube
    GM172995Courtesy of GENERAL MOTORS COMPANY
  14. Connect the PCV valve hose assembly to the intake manifold and the valve rocker arm cover.
    15. Fig 8: View Of Vacuum Brake Booster Hose
    GM346148Courtesy of GENERAL MOTORS COMPANY
  15. Connect the power brake booster vacuum hose to the intake manifold.
    16. Fig 9: Engine Wiring Harness Retainer Nuts
    GM310243Courtesy of GENERAL MOTORS COMPANY
  16. Position the engine wiring harness and engine wiring harness brackets.
  17. Install the stud holding the engine wiring harness bracket to the rear of the right cylinder head.

    Tighten 

    Tighten the engine wiring harness bracket stud to 25 N.m (18 lb ft).

  18. Install the nut holding the engine wiring harness bracket to the stud at the EVAP canister purge solenoid valve.

    Tighten 

    Tighten the engine wiring harness bracket nut to 9 N.m (80 lb in).

  19. Install the nut and the ground wire on the engine wiring harness bracket stud at the rear of the right cylinder head.

    Tighten 

    Tighten the ground wire nut to 16 N.m (12 lb ft).

    20. Fig 10: View Of Engine Wiring Harness Bracket & Nuts
    GM310241Courtesy of GENERAL MOTORS COMPANY
  20. Install the engine wiring harness bracket on the upper intake manifold studs.
  21. Install the engine wiring harness bracket nuts.

    Tighten 

    Tighten the engine wiring harness bracket nuts to 12 N.m (106 lb in).

    22. Fig 11: EGR Valve Connector, A/C Compressor Clutch Connector And A/C Pressure Switch Connector
    GM491821Courtesy of GENERAL MOTORS COMPANY
  22. Connect the following electrical connections:
    • The A/C compressor clutch (1), if equipped
    • The A/C pressure switch (4), if equipped
    • The EGR valve (2)
    23. Fig 12: Throttle Position (TP) sensor Connector, Idle Air Control (IAC) Motor Connector And Fuel Meter Body Assembly Connector
    GM491817Courtesy of GENERAL MOTORS COMPANY
  23. Connect the following electrical connections:
    • The throttle position (TP) sensor (1)
    • The idle air control (IAC) motor (2)
    • The fuel meter body assembly connector (3)
    24. Fig 13: Manifold Absolute Pressure (MAP) Sensor Connector And EVAP Canister Purge Solenoid Valve Connector
    GM491816Courtesy of GENERAL MOTORS COMPANY
  24. Connect the following electrical connections:
    • The manifold absolute pressure (MAP) sensor (2)
    • The EVAP canister purge solenoid valve (1)
    25. Fig 14: View Of Accelerator Control Cable Bracket
    GM398030Courtesy of GENERAL MOTORS COMPANY
  25. Install the accelerator control cable bracket with the accelerator control cable and the cruise control cable and the nuts to the throttle body.

    Tighten 

    Tighten the accelerator control cable bracket nuts to 9 N.m (80 lb in).

  26. Install the engine wiring harness clip to the accelerator control cable bracket.
  27. Install the cruise control cable, if equipped to the throttle shaft and the accelerator control cable bracket. Refer to Cruise Control Cable Replacement (V6) in Cruise Control.
    28. Fig 15: Expanded View Of Accelerator Cable From The Engine Cable Bracket
    GM325557Courtesy of GENERAL MOTORS COMPANY
  28. Install the accelerator cable to the engine cable bracket.
    29. Fig 16: Identifying Accelerator Cable/Throttle Body Lever
    GM325556Courtesy of GENERAL MOTORS COMPANY
  29. Install the accelerator cable to the throttle body lever.
    30. Fig 17: Accelerator Cable Routing Bracket
    GM26764Courtesy of GENERAL MOTORS COMPANY
  30. Install the accelerator cable to the cable routing bracket.
    31. Fig 18: Secondary Air Injection (AIR) Crossover Pipe
    GM398868Courtesy of GENERAL MOTORS COMPANY
  31. Connect the AIR crossover pipe to the AIR pipe assemblies.
    32. Fig 19: View Of Air Cleaner Outlet Duct
    GM489176Courtesy of GENERAL MOTORS COMPANY
  32. Align the hinge clip with the lip on the throttle body.

    Install the air inlet tube and resonator to the throttle body by pivoting the air inlet tube and resonator downward until the mounting stud is through the hole in the air inlet tube.

    33. Fig 20: View Of Air Cleaner Adapter Nut
    GM489179Courtesy of GENERAL MOTORS COMPANY
  33. Install the resonator retaining wing nut.
  34. Connect the PCV hose to the air cleaner outlet duct.
    35. Fig 21: View Of MAF/IAT Sensor Assembly Harness Connector (4.3L Engine)
    GM373468Courtesy of GENERAL MOTORS COMPANY
  35. Connect the MAF/IAT sensor assembly harness connector.
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.