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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 538 (ENGINE CONTROL SYSTEM & FUEL SYSTEM - 6.6L LMM - INTRODUCTION)REPAIR INSTRUCTIONSINTAKE AIR HEATER 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 does not describe the selected car, but rather 6 other vehicles, including the 2009 GMC Savana Special, 2009 GMC Savana Camper Special, 2009 GMC Savana, 2009 Chevrolet RV Cutaway, and 2009 Chevrolet Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Engine Wiring Harness Electrical Connector
    GM1862030Courtesy of GENERAL MOTORS CORP.
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  2. Remove the charge air cooler outlet pipe. Refer to Charged Air Cooler Hoses/Pipes Replacement (Inlet) or Charged Air Cooler Hoses/Pipes Replacement (Outlet) .
  3. Disconnect the engine wiring harness electrical connector (1) from the intake air heater (IAH).
  4. Disconnect the engine wiring harness electrical connector (2) from the intake air valve.
  5. Remove the nut and the positive battery cable from the IAH.
    6. Fig 2: Identifying Intake Air Valve Bolts
    GM1862033Courtesy of GENERAL MOTORS CORP.
  6. Remove the intake air valve bolts and valve.
  7. Fig 3: View Of IAH Gasket
    GM1862035Courtesy of GENERAL MOTORS CORP.

    Remove the IAH and 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.