Genuine 2005 Chevrolet Astro Intake Manifold

2005 Chevrolet Astro Parts Questions & Experts Answers

• Q: How to disconnect the battery and remove the intake manifold in four cylinder engine on 2005 Chevrolet Astro?

  A: Disconnect the cable from the negative battery terminal and remove the engine cover, ensuring to disable the anti-theft feature on models equipped with such systems before disconnecting the battery. Remove the air cleaner assembly, then take out the PCV valve and hose. Drain the cooling system and detach the fuel lines, vacuum lines, and wire leads from the fuel injection assembly, being prepared to catch any fuel and plugging the line to prevent contamination. After noting the installation, disconnect the fuel injection throttle linkage along with the cruise control and TV linkage if applicable. Tag and disconnect all remaining vacuum lines and wires connected to components on the manifold, and remove the coolant hoses. Take out the ignition coil, unbolt the alternator and bracket, and set them aside. Remove the mounting bolts to separate the manifold from the cylinder head without prying to avoid damaging the gasket sealing surfaces. Use a scraper to remove the old intake manifold gasket, ensuring no material remains on the mating surfaces. If installing a new manifold, transfer all components from the old manifold to the new one. Clean the cylinder head and manifold gasket surfaces with lacquer thinner or acetone, ensuring all gasket material and sealing compound are removed. Apply a thin coat of RTV sealant to the mating surfaces, ensuring it does not spread into air or coolant passages during installation. Place a new gasket on the manifold, hold it in position against the cylinder head, and install the mounting bolts finger tight. Tighten the bolts gradually in the correct sequence until they reach the specified torque. Reinstall the remaining components in reverse order of removal, fill the radiator with coolant, start the engine, and check for leaks.