Astro Van M V6-262 4.3L VIN W CPI (1992)
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Throttle position sensor.
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Idle air control motor.
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Manifold absolute pressure sensor.
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Communicator valve.
5. Throttle linkage from upper intake manifold.
6. Ignition coil.
7. PCV hose at upper intake manifold.
8. Vacuum hoses at front and rear of upper intake manifold.
9. Air conditioning line at compressor (if equipped).
10. Upper intake manifold bolts and studs.
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Mark the location of all studs for proper reassembly.
11. Upper intake manifold.
Lower Intake Manifold Removal
Remove or Disconnect (figure 18)
1. Distributor wiring and distributor.
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Mark the relationship of the distributor housing and rotor for proper reassembly.
2. Upper radiator house at thermostat housing.
3. Heater hose at lower intake manifold.
4. Fuel supply and return lines at rear of lower intake manifold.
5. Wire harness, including:
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Fuel injectors.
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Exhaust gas recirculation valve.
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Coolant temperature sensor.
6. Lower intake manifold bolts.
7. Lower intake manifold.
Clean
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Old pieces of gasket from the gasket surfaces.
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Excessive carbon build-up in the exhaust passages.
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Scale and deposits from coolant passages.
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EGR passage of excessive carbon deposits.
Inspect
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Manifold for cracks, broken flanges, and gasket surface damage.
Lower Intake Installation
Install or Connect (Figure 18 and 19)
1. Gaskets to the cylinder head with the port blocking plates facing the rear of the engine and "this side up" stamp facing up.
2. RTV to the front and rear sealing surfaces on the block. Apply a 5 mm (3/16 inch) bead of RTV (GM P/N 1052366 or equivalent) to the front and
rear of the block. Extend the bead 13 mm (1/2 inch) up each cylinder head to seal and retain the gaskets.
3. Lower intake manifold to engine.
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Apply sealer, GM P/N 1052080 or equivalent, to the lower intake manifold bolts.
4. Lower intake manifold bolts. Tighten bolts to 48 Nm (35 ft. lbs) using the tightening sequence shown in figure 19.
5. Wire harness including:
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Fuel injector.
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Exhaust gas recirculation valve.
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Coolant temperature sensor.
6. Fuel supply and return lines to rear of the lower intake manifold.
7. Heater hose to lower intake manifold.
8. Upper radiator hose to thermostat housing.
9. Distributor wiring and distributor.
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Note the relationship of the distributor housing and rotor made at disassembly.
Upper Intake Installation
Install or Connect (Figures 18 and 20)
1. Upper intake manifold gasket with green sealing lines facing up.
2. Upper intake manifold.
