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Removing Astro Intake Manifold

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Glenn F.

Member
I'm afraid my trusty '88 Chevy Astro is junk. Broke off a thermostat housing bolt tonight attempting to change the thermostat. Anyone know how many hours the book allows to remove & remount the intake manifold?

Thanks,
Glenn F.
 
Don't think the flat rate manual will be close, you broke off the first bolt, that's an indication a few more will give you trouble, and some of those go into the heads. If only one bolt is going to give you trouble it'll usually be the last, if the first gives you trouble fill your hand and be prepared for a battle.
 
Weld a washer to the broken bolt, let it cool, add "loosen juice" and unscrew it. Repeat, if necessary.
 
The throttle body ain't gonna burn up! To be safe, pull the fuel pump fuse and start it to use up mist of the fuel.

Then, wrap a couple of wet rags around it and weld away.
 
(quoted from post at 04:55:55 03/19/15) I'm afraid my trusty '88 Chevy Astro is junk. Broke off a thermostat housing bolt tonight attempting to change the thermostat. Anyone know how many hours the book allows to remove & remount the intake manifold?

Thanks,
Glenn F.
Click to expand...

I had one to dodat on a astro I spent hours trying not to ring it off but it happen... I would have been better off to snap it off from the get go... I drilled and tapped never tried the weld'N trick I don't think it would have worked... Its not gonna blow up give it a try...

If you have to remove it its set down work and not that bad a job...

4/5 hr and remember the restrictions in the intake gasket go to the rear..
 
I'm with Bob on this.....burn off fuel, wet rags or old towels, and weld something to it. I had a drain plug giving me fits, welded a bolt to the plug, and came right out with a wrench like it was never stuck. Heat was the trick. Betting it will work for you, saving a lot of time. Let it cool a bit before trying.
 
To replace the int manifold, mitchell guide calls for 4.1hrs then add 0.2hrs for a/c interference, add 0.2hrs for speed control interference, add 0.5hrs where electrical engine system (TBI) interferes. Total all of those equals 5.0hrs, for replacement, intake gasket replacement was 0.2hrs less with the same add ons.

Keep in mind that is under perfect conditions, with no other repairs needed.
 
(quoted from post at 01:55:55 03/19/15) I'm afraid my trusty '88 Chevy Astro is junk. Broke off a thermostat housing bolt tonight attempting to change the thermostat. Glenn F.
Click to expand...

Ouch, did this on a Ford 5.4 in an Expedition. But the bolts are long and go through a crossover piece that is attached to the intake, so nothing to grab or weld to. And of course the crossover is bolted to the intake from below so it can't come off separately. I'm going to try to soak the bolt holes in PB Blaster for awhile and left hand drill it to see if I can get the small remaining pieces of the bolts out before removing the intake. There is a good video on YouTube that shows the whole intake removal procedure, you might find something too for your Chevy that might give you an idea on how long it would take. Good luck with it.
 
I have no idea. Broken bolts add onto book time.

This is why I have a stated policy of not working under the hood of a minivan, even if it's a job I'd willingly do on a passenger car or pickup.
 
I Was able to heat up to he area & remove the broken bolt with the tip of my vice grip!! Now I just need to reassemble.

Glenn F.
 
(quoted from post at 01:29:31 03/20/15) I removed it. I am very thankful I was able to get that bolt out though!

Glenn F.
Click to expand...

Good for you!! 4 hrs to change the intake my butt! You can spend that much time just changing the plugs on one of those.
 
You do realize that if you had taken it to a shop - and they did the same they would likely have charged you the shop rate anyhow? I used to know a guy that worked at a dealership and he bragged on how he could do some jobs in half the time the shop rate showed, yet the shop charged the customer full price for the job. Funny though that it does not usually work the other way around and if any issue arises they seem to not hesitate to add. Glad you were able to get it done fairly easily.
 
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