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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 143 (ENGINE CONTROLS AND FUEL - 3.5L - INTRODUCTION (2 OF 2))REPAIR INSTRUCTIONSTHROTTLE BODY ASSEMBLY REPLACEMENTREMOVAL PROCEDURE
2008 Chevrolet Chevy Express G3500, Van Passenger Extended

Removal Procedure

2008 Chevrolet Chevy Express G3500, Van Passenger ExtendedSECTION Removal Procedure
WARNING: This page is about a different car, the 2008 Chevrolet Malibu Classic. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Do not use solvent of any type when cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as damage to the gasket surfaces and throttle body assembly may result.
Use care in cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as sharp tools may damage the gasket surfaces.
    Fig 1: Identifying Engine Wiring Harness Electrical Connector
    GM1774876Courtesy of GENERAL MOTORS CORP.
  1. Remove the intake manifold cover. Refer Intake Manifold Cover Replacement .
  2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  3. Disconnect the engine wiring harness electrical connector (2) from the electronic throttle control (ETC).
    4. Fig 2: Identifying Heater Inlet And Outlet Pipe Nuts
    GM1774995Courtesy of GENERAL MOTORS CORP.
  4. Remove the heater inlet and outlet pipe nuts (1).
  5. Remove the heater inlet and outlet pipe bracket from the throttle body studs. Reposition the pipes.
    6. Fig 3: View Of Throttle Body Components
    GM1775003Courtesy of GENERAL MOTORS CORP.
  6. Remove the throttle body bolts (9) and nuts (10).
  7. Remove the throttle body (8).
  8. Remove and discard the throttle body gasket (7).
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.