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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 950 (Engine Controls - 6.6L (Lb7) (Introduction)) >> Repair Instructions >> Intake Air Heater (IAH) Relay Replacement (California Emissions) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) in Engine Electrical.
  2. Loosen the outlet duct clamp at the upper intake manifold.
  3. Remove the upper intake manifold cover from the outlet duct.
  4. Remove the upper intake manifold cover.
    5. Fig 1: View Of Upper Intake Manifold Cover, Outlet Duct & Clamp
    GM813243Courtesy of GENERAL MOTORS CORP.
  5. Disconnect the engine harness electrical connector (2).
  6. Disconnect the intake air heater (IAH) relay electrical connector (3).
    7. Fig 2: Engine Harness Electrical Connector & IAH Relay Electrical Connector
    GM757209Courtesy of GENERAL MOTORS CORP.
  7. Reposition the battery cable boots (1).
    8. Fig 3: Battery Cable Boots
    GM1198931Courtesy of GENERAL MOTORS CORP.
  8. Remove the battery cable nuts and cables from the IAH relay controller. Reposition the cables.
  9. Remove the IAH relay controller bolts (2).
    10. Fig 4: Battery Cable Boots & IAH Relay Controller Bolts
    GM1198934Courtesy of GENERAL MOTORS CORP.
  10. Remove the IAH relay controller.
  11. Remove the IAH relay controller cover.
    12. Fig 5: IAH Relay Controller Cover
    GM1198936Courtesy of GENERAL MOTORS CORP.
  12. Remove the IAH relay controller nuts and washers.
    13. Fig 6: IAH Relay Controller Nuts And Washers
    GM1198938Courtesy of GENERAL MOTORS CORP.
  13. Using 2 screwdrivers, disengage the IAH relay assembly from the controller housing.
    14. Fig 7: Disengaging IAH Relay Assembly From Controller Housing Using 2 Screwdrivers
    GM1198939Courtesy of GENERAL MOTORS CORP.
  14. Remove the IAH relay assembly from the housing.
    15. Fig 8: IAH Relay Assembly & Housing
    GM1198940Courtesy of GENERAL MOTORS CORP.
  15. Remove the IAH relay.
    16. Fig 9: IAH Relay
    GM1198942Courtesy of GENERAL MOTORS CORP.
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