OEM 2001 Chevrolet Astro Intake Manifold

2001 Chevrolet Astro Parts Questions & Experts Answers

• Q: How to replace the upper intake manifold on 2001 Chevrolet Astro?

  A: In order to remove the upper Intake Manifold, you should start with the removal of the engine cover and the air cleaner outlet duct from the Throttle Body. Remove the accelerator control cable and the cruise control cable, if available, from the throttle shaft and the accelerator control cable bracket. Refrain the PCV Valve Hose from the Intake Manifold and also the valve rocker arm cover, and also the nut that secures the a/c hose bracket to the Intake Manifold stud, and remove them. Then, disassemble the nut fixing the engine wiring harness bracket to the Intake Manifold stud as well as the bracket itself. Disconnect the electrics for a/c compressor clutch, a/c high pressure cutoff switch, throttle position ( TP ) sensor, idle air control ( IAC ) motor, the fuel meter body connect, manifold absolute pressure ( MAP ), sensors, and evap canister purge solenoid valve. Unclip the engine wiring harness bracket from the stud at the evap canister purge solenoid valve and route the engine wiring harness out of harm's way. Remove the evap canister purges valve, take one vacuum hose off the Intake Manifold, and remove the bolt securing the transmission filler tube to accelerator control cable bracket. Delete the accelerator control cable bracket in the Throttle Body and Intake Manifold, as well as the fuel lines at the fuel meter body assembly. Take off the studs from the upper Intake Manifold and the upper Intake Manifold itself together with the upper Intake Manifold gasket, disposing of the gasket and seal from the fuel meter body assembly. Clean all sealing surfaces and the inside of the upper Intake Manifold by using a shop towel and cleaning solvent, inspect them for any cracks or damage in bolt hole thread inserts. If you have to remove the upper Intake Manifold, turn and remove the pcv valve cover, and discard the seal. If the Throttle Body and MAP Sensor were removed, install them and a new seal (O-ring) on the pcv valve cover, lubricate it with clean engine oil and screw it into the upper inlet manifold. Mount a new seal on the fuel meter body assembly, lubricate it and put a new gasket for the upper Intake Manifold to lower Intake Manifold in the groove of the upper Intake Manifold before putting the upper Intake Manifold onto lower Intake Manifold. If it is necessary to reuse fasteners, threadlock gm p/n 12345382 or its equivalent on upper Intake Manifold attaching bolts. Tighten yours upper Intake Manifold attaching studs to 5 nm (44 in lbs.) then to 9nm (80 in lbs.). Replace and tighten the fuel lines, evap canister purge valve, and the accelerator control cable bracket, studs, and nuts to the Intake Manifold and Throttle Body to 12 nm (106 inch lbs.) for the bracket nuts and studs. Attach the vacuum hose to the manifold intake, replace and bolt in the transmission fluid fill tube to the accelerator control cable bracket, tighten bolt to 6 nm (53 inch lbs). Position the engine wiring harness and reconnect the electrical connectors for the a/c compressor clutch, a/c high pressure cutoff switch, throttle position (TP) sensor, idle air control (IAC) motor, fuel meter body assembly connector, map sensor, and evap canister purge so great valve. Mount the engine wiring harness bracket and nut to the Intake Manifold stud and tighten the nut to 12 nm (106 inch lbs.), and the a/c hose bracket and nut to the Intake Manifold stud and tighten to 5 nm (44 inch lbs) if equipped. Screw in the engine wiring harness bracket and nut onto the stud at the evap canister purge solenoid valve, torque it to 8 nm (71 inch lbs.). Finally attach the PCV Valve Hose assembly to the Intake Manifold and valve rocker arm cover, and reinstall the cruise control cable if it is present, attach the accelerator control cable and complete the job by reinstalling the engine cover.