2002 GMC C3500 HD 8.1 G, AutomaticFACTORY OEM SERVICE PROCEDURE

Installation Procedure

  1. Install a new throttle body gasket.
  2. Install the throttle body assembly.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.

    Important:  Always use a torque wrench in order to obtain the proper torque.

  3. Install the throttle body attaching bolts.

    Tighten 

    Tighten the throttle body attaching bolts to 10 N.m (89 lb in).

    Important:  Ensure that the electrical connector to throttle body motor and the connector seal are properly installed and not damaged.

  4. Connect the TP sensor harness connector.
  5. Connect the throttle actuator motor harness connector.
  6. Install the air induction assembly to the throttle body.
  7. With the vehicle not in reduced engine power, turn ON the ignition with the engine OFF. Inspect for complete throttle opening and closing positions. Use a scan tool to monitor the throttle angles while operating the accelerator pedal to open and close the throttle. The accelerator pedal should operate freely without binding between full closed throttle and wide open throttle.
  8. Start the engine.
    Fig 1: Throttle Body & Gasket
    G01598894Courtesy of GENERAL MOTORS CORP.
Factory Service Tools

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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.