GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2000 🢒 Chevy Suburban - 2WD 🢒 Engine 🢒 Engine Mechanical - 4.8L, 5.3L, and 6.0L 🢒 Intake Manifold Replacement

Removal Procedure

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Drain the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
  3. Remove the engine sight shield. Refer to Upper Intake Manifold Sight Shield Replacement .

    4. Caution: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.

    In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.


    Object Number: 260101 Size: SH
  4. Disconnect the accelerator control cable and the cruise control cable, if equipped, from the throttle shaft. Refer to Accelerator Control Cable Replacement in Engine Controls.
  5. Position the cables to the side.
  6. Remove the engine sight shield mounting bracket and the bolts.

    7. Object Number: 307286 Size: SH
  7. Remove the air cleaner duct.

    8. Object Number: 412343 Size: SH
  8. Remove the inlet coolant hose from the throttle body.

    9. Object Number: 220621 Size: SH
  9. Remove the vapor vent tube hose from the throttle body.
  10. Remove the exhaust gas recirculation (EGR) pipe bracket. Refer to Exhaust Gas Recirculation Pipe Replacement in Engine Controls-4.8L, 5.3L, 6.0L.

    11. Object Number: 310125 Size: SH
  11. Open the large electrical harness retainer, then remove one M6 nut in order to separate the engine harness from the intake manifold.

    12. Object Number: 310126 Size: SH
  12. Disconnect the following electrical connectors:
    13. • Eight fuel injector connectors
    • Idle air control (IAC) motor
    • Throttle position (TP) sensor
    • Evaporative emission (EVAP) canister purge solenoid
    • Manifold absolute pressure (MAP) sensor
  13. Set the electrical harness aside.
  14. Disconnect the purge solenoid vent tube from the solenoid by squeezing the retainer, then release the tube from the solenoid. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement in Engine Controls - 4.8L, 5.3L, 6.0L.
  15. Disconnect the fuel pipes from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service in Engine Controls - 4.8L, 5.3L, 6.0L.

    16. Object Number: 382483 Size: SH
  16. Remove the vacuum brake booster hose, if equipped.

    17. Object Number: 260078 Size: SH
  17. Remove the positive crankcase ventilation (PCV) valve (2) and hose (1).
  18. Remove the intake manifold from the engine. Refer to Intake Manifold Removal .
  19. Clean and inspect the intake manifold and all sealing surfaces. Refer to Intake Manifold Cleaning and Inspection .

Installation Procedure

    Object Number: 382483 Size: SH
  1. Install the intake manifold to the engine. Refer to Intake Manifold Installation .
  2. Install the vacuum brake booster hose, if equipped.

    3. Object Number: 260078 Size: SH
  3. Install the PCV valve (2) and the hose (1).
  4. Connect the fuel pipes to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service in Engine Controls -- 4.8L, 5.3L, 6.0L.
  5. Connect the purge solenoid vent tube to the purge solenoid. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement in Engine Controls -- 4.8L, 5.3L, 6.0L.

    6. Object Number: 310125 Size: SH

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  6. Install the engine electrical harness and nut.

    7. Tighten
    Tighten the engine wiring harness nut to 10 N·m (89 lb in).


    Object Number: 310126 Size: SH
  7. Route the harness over the engine, then install the following connectors.
    8. • EVAP
    • TP
    • MAP
    • Fuel pipes
    • IAC
    • Eight fuel injector connectors

       Caution: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.

    In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.

    • Install the engine sight shield mounting bracket and the bolts.
    • Install the accelerator control cable and the cruise control cable, if equipped, to the throttle shaft. Refer to Accelerator Control Cable Replacement in Engine Controls.
  8. Install the engine sight shield. Refer to Upper Intake Manifold Sight Shield Replacement .
  9. Install the EGR pipe bracket. Refer to Exhaust Gas Recirculation Pipe Replacement in Engine Controls-4.8L, 5.3L, 6.0L.

    10. Object Number: 220621 Size: SH
  10. Install the vapor vent tube hose to the throttle body.

    11. Object Number: 412343 Size: SH
  11. Install the coolant hose to the throttle body.

    12. Object Number: 307286 Size: SH
  12. Install the air cleaner duct.
  13. Fill the engine with coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
  14. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.