OEM 2003 Chevrolet Astro Intake Manifold

2003 Chevrolet Astro Parts Questions & Experts Answers

• Q: What are the steps involved in the removal and installation of the fuel injector assembly and upper intake manifold on 2003 Chevrolet Astro?

  A: The weak retainers that secure the fuel injectors in the Intake Manifold will function properly during installation because the upper intake will fully seat the injectors so they cannot escape from their lower manifold position. The threads of the fuel meter body bracket bolt must be treated with threadlock (GM P/N 12345382 or Canadian P/N 10953489) if you plan to reuse the bolt. After application, install both the fuel meter body bracket and bolt and tighten them to 10 nm (89 lb.in.). Position the six injectors in the correct lower Intake Manifold bores through the sequence (3, 5, 1, 2, 4, 6) and verify proper seating and lock afterward. Fit the electrical connections of the injectors without interference while facing towards the center of the Intake Manifold and adjust them slightly inboard to prevent wire tension. Align the electrical injector connections to minimize wire tension while facing toward the center of the Intake Manifold structure. Modifiy connector direction toward the inside of the manifold to prevent wiring tension. Place a new gasket between the upper and lower intake manifolds before setting the upper Intake Manifold into the lower manifold groove. To reuse fasteners apply threadlock compound gm p/n 1234582 or canadian p/n 10953489 to upper Intake Manifold attaching studs before installation with a torque of 5 nm (44 lb.in.) on first pass and 9 nm (80 lb.in.) on the final pass. To install evap canister purge solenoid valve studs with reused fasteners, apply threadlock (GM P/N 12345382 or Canadian P/N 10953489) to the stud threads, then fasten the valve and studs with 10 nm (89 lb.in.) torque. Screw the engine wiring harness bracket and secure its nut using 12 nm (106 lb.in.) torque. After installing the new fuel seals (black O-rings) into the fuel meter body you should add the new spacer rings and flat washers before setting in the new fuel seals (yellow O-rings) and then install the oil-retention tools. Begin by inserting the fuel pipe into the fuel meter body before applying the fuel pipe retainer bracket onto the fuel pipe followed by fastening the fuel pipe retainer bracket nuts . To reuse the fastener apply gm p/n 12345382 or canadian p/n 10953489 threadlock on the fuel pipe bolt threads. Install the bolt and tighten fuel pipe bracket nuts to 3 nm (27 lb.in.) while torqueing the fuel pipe bolt to 6 nm (53 lb.in.). Install a new manifold absolute pressure (MAP) sensor seal onto the MAP Sensor before applying a small amount of clean engine oil to the seal. Next, insert the MAP Sensor into the upper Intake Manifold. Screw the Ignition Coil into position and thread the studs until torque reaches 12 nm (106 lb.in.). Apply gm p/n 12346004 or canadian p/n 10953480 sealant to the threads of the ect sensor plug or sensor before installing it into the lower Intake Manifold front section with a torque of 20 nm (15 lb.ft). Install the engine coolant Thermostat followed by the water outlet (1 or 2) and accompanying studs while tightening both to 25 nm (18 lb.ft). Set a fresh Throttle Body Gasket into the upper Intake Manifold groove before inserting the Throttle Body. To reuse fasteners apply threadlock gm p/n 12345382 or canadian p/n 10953489 onto Throttle Body attaching studs before installing the accelerator control cable bracket along with the studs and nuts. Torque all fasteners to the following specifications: accelerator control bracket studs to Intake Manifold 6 nm (53 lb.in.) and nuts to 12 nm (106 lb.in.) and Throttle Body attaching studs to 12 nm (106 lb.in.).