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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 2072 (ENGINE CONTROL SYSTEM & FUEL SYSTEM - 6.6L (LMM) - REPAIR INSTRUCTIONS)REPAIR INSTRUCTIONSINTAKE AIR HEATER REPLACEMENTREMOVAL PROCEDURE
2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6

Removal Procedure

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6SECTION Removal Procedure
WARNING: This page is about a different car, the 2010 GMC Sierra, 2010 GMC Cab & Chassis Sierra, 2010 Chevrolet Silverado, and 2010 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Upper Intake Manifold Brace & Bolts
    GM1871113Courtesy of GENERAL MOTORS CORP.
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) or Battery Negative Cable Disconnection and Connection (Dual Batteries) or Battery Negative Cable Disconnection and Connection (Auxiliary Battery) .
  2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
  3. Remove the exhaust gas recirculation (EGR) valve motor. Refer to Exhaust Gas Recirculation Valve Motor Replacement .
  4. Remove the upper intake manifold brace bolts and brace.
    5. Fig 2: View Of Engine Wiring Harness Clip & Bolt
    GM1871193Courtesy of GENERAL MOTORS CORP.
  5. Remove the engine wiring harness clip (1) from the intake manifold tube.
  6. Remove the engine wiring harness clip bolt (2) from the intake manifold tube.
    7. Fig 3: View Of Intake Air Heater (IAH) & Manifold Absolute Pressure (MAP) Sensor Electrical Connectors
    GM1871195Courtesy of GENERAL MOTORS CORP.
  7. Disconnect the engine wiring harness electrical connector (1) from the intake air heater (IAH).
  8. Disconnect the engine wiring harness electrical connector (2) from the manifold absolute pressure (MAP) sensor.
  9. Reposition the engine wiring harness branches out of the way.
    10. Fig 4: View Of Engine Wiring Harness Lead, Nut & Cover
    GM1871196Courtesy of GENERAL MOTORS CORP.
  10. Open the IAH harness lead cover (2).
  11. Remove the engine wiring harness lead nut (1) from the IAH stud.
  12. Remove the engine wiring harness lead (3) from the IAH stud.
    13. Fig 5: View Of IAH, Bolts & Nuts
    GM1871197Courtesy of GENERAL MOTORS CORP.
  13. Remove the IAH bolts (1) and nuts (2).
  14. Remove the intake manifold front tube and IAH from the intake manifold rear tube.
  15. Remove the IAH (3) from the intake manifold front tube studs.
  16. Remove and discard the IAH gasket.
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.