OEM 2005 Chevrolet Astro Intake Manifold

2005 Chevrolet Astro Parts Questions & Experts Answers

• Q: How to replace the upper intake manifold on 2005 Chevrolet Astro?

  A: To replace the upper Intake Manifold, you should start with the removal of the throttled body with the help of removing the air cleaner outlet duct and the engine cover. Remove the accelerator control cable and cruise control cables from the throttle shaft and accelerator control cable bracket. Gently pull off the PCV Valve Hose assembly, the a/c hose bracket, and the engine wiring harness bracket from the Intake Manifold. Disconnect the electrical connectors: a/c compressor clutch , a/c high pressure cutoff switch , throttle position (TP) sensor , idle air control (IAC) motor , fuel meter body assembly connector , manifold absolute pressure (MAP) sensor and evap canister purge solenoid valve. Bring the engine wiring harness away, remove the vacuum hose from the engine Intake Manifold and the accelerator control cable bracket together with fuel lines. Remove the studs and the upper Intake Manifold, as well as the gasket and seal, without immersing the manifold in the cleaning solvent. Clean all the sealing surfaces and also inspect the manifold for damage. If replacing the manifold, remove pcv valve cover and dispose of seal. For installation, begin by installing the throttle-body, and MAP Sensor if removed, then pcv valve cover using new seal lubricated by using clean engine oil. Mount a new seal onto a new fuel meter body assembly and a new upper Intake Manifold gasket in the groove of the upper Intake Manifold of the body before installing the upper Intake Manifold over the lower Intake Manifold. If reusing fasteners, dab with thread lock gm p/n 12345382 or equivalent and then instal the attaching stolets which should first be threaded on to 5 nm (44 inch lbs.) and then to 9 nm (80 inch lbs.). Reattach and connect the fuel lines, evap canister purge valve, and the accelerator control cable bracket, and tighten to 12 nm (106 inch lbs.). Reconnect the vacuum hose, install the transmission fluid fill tube and bolt, and place the engine wiring harness. Connect the electrical connectors of the following components: 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 solenoid valve. Install the engine wiring harness bracket and nut to 12nm (106 inch lbs), the a/c hose bracket and nut to 5 nm (44 inch lbs), and the engine wiring harness bracket at the evap canister purge solenoid valve to 8 nm (71 inch lbs). Finally, bring back the PCV Valve Hose assembly, install (if is equipped) cruise control cable, encourage control cable, air cleaner outlet duct and at last attach the engine cover.