OEM 2003 Chevrolet Venture Intake Manifold

2003 Chevrolet Venture Intake Manifold Parts and Q&A

• Q: How to replace the lower intake manifold on 2003 Chevrolet Venture?

  A: To replace the lower Intake Manifold, gather the necessary tools: torque angle meter (J 36660-A). The repair process begins with upper Intake Manifold removal before tackling the engine left and right side valve rocker arm covers. Use masking tape to label each Fuel Injector wiring harness connector then disconnect the wiring harness from the engine coolant temperature (ECT) sensor. To start remove the Fuel Injector and manifold air pressure (MAP) along with ect wiring harness before taking off fuel feed and return pipe from the Fuel Injector rail followed by removing the Fuel Injector rail. Power steering hoses should never be detached from the Power Steering Pump; however, professionals should remove this pump from the front engine cover and place it aside for later use. Remove the heater inlet pipe with heater hose from the lower Intake Manifold along with the inlet Radiator Hose from the engine and the thermostat bypass hose from the lower Intake Manifold pipe. First disconnect the lower Intake Manifold bolts then remove the lower Intake Manifold. After that, loosen the valve rocker arms before removing the push rods. Remove both lower Intake Manifold gaskets and seals then clean the gasket and seal surfaces of engine block and cylinder heads for inspection of the lower Intake Manifold. To install a new lower Intake Manifold you need to remove both the ect sensor and thermostat. To secure installation you must spread a 0.08 - 0.11 inch (8 - 12 mm) bead of rtv sealer gm p/n 12345739 or similar product across each ridge where the front and rear of the lower Intake Manifold meets the engine block. Install the lower Intake Manifold gaskets, followed by the push rods and valve rocker arms, tightening the valve rocker arm bolts using the torque angle meter (J 36660-A) to 19 nm (14 ft. Lbs.) plus 30 degrees. Sand a rectangular portion of the Intake Manifold and apply rtv sealer gm p/n 12346141 (Canadian P/N 89022195), forming a 8-10 mm (0.31-0.39 in) wide, 3.0-5.0 mm (0.12-0.20 in) thick droplet at the block joint. The lower Intake Manifold installation requires starting with vertical bolt tightening after which diagonal bolts get tightened to stop oil leakage through the use of new lower Intake Manifold bolts. The torque specification involves a 2-step process: the vertical lower Intake Manifold bolts should first receive a torque of 7 nm (62 lb in) followed by the diagonal bolts at 7 nm (62 lb in). Next, torque the vertical bolts to 13 nm (115 lb in) while tightening the diagonal bolts to 25 nm (18 lb ft). The installation process requires attaching the temperature bypass hose to the inlet Radiator Hose and the heater inlet pipe to a lower Intake Manifold position using heater hose installation. Reinstall the Power Steering Pump and Fuel Injector rail after connecting their respective fuel feed and return pipes to the Fuel Injector rail. Sun ensure proper engine function and avoid excess exhaust by verifying all Fuel Injector wiring harness connector pairings lead to their proper destinations. The final steps include installing the Fuel Injector followed by connecting the map and ect wiring harnesses while completing the installation of the wiring harness to the ect sensor, engine right and left side valve rocker arm covers, and inserting the upper Intake Manifold.