Question about 2002 Mercury Cougar

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Is it Possible for the Upper Intake Manifold/ Plenum to warp?

I had to put a lot of gasket maker to seal the Upper Intake Manifold/ Plenum just so the vehicle would stay running, but hasn't kept the Lean code from reappearing. Is it possible for it to warp, because every single bolt that holds the Upper Manifold on is tight, yet it does not sit flush on the Lower Manifold.

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  • Mercury Master
  • 2,485 Answers

You could take it to a machinery shop and have it machined but you would have to do both surfaces.

Posted on Dec 11, 2014

Testimonial: "Is it possible for the Upper Manifold to Warp?"

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6ya6ya
  • 2 Answers

SOURCE: I have freestanding Series 8 dishwasher. Lately during the filling cycle water hammer is occurring. How can this be resolved

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Posted on Jan 02, 2017

chuck943
  • 783 Answers

SOURCE: Failed Emissions test. OBD

Rich:

The trick to setting all the monitors is:
Make sure you have more than 1/4 tank of fuel but no more than 3/4.
Clear codes then Do Not cycle key off. Start vehicle and drive,make sure you do at least 2 minutes of steady spead between 40-50 mph and at least 2 minutes at 50-65 mph, usually about a 20 to 25 mile drive will set them..
If you turn the ignition off before the monitors complete then EVAP will have to see a 6 hour cold soak before it will attempt to run again.

Posted on Mar 24, 2009

  • 6982 Answers

SOURCE: V6 engine failure

Doubtful if anyone poured water in there. Your head gasket failed and allowed coolant to fill the cylinder overnight. This is called hydrolock. Coolant cannot be compressed so when the compression stroke occurs, the weak point is the connecting rod or the piston top which can simply cave in. This can also happen to vehicles when driving through flooded areas if the air intake is too low. Head resurfacing is normal and best way to prevent future gasket failure. The only thing you did not mention is if the mechanic checked the affected cylinder bore for bulge. The additional pressure that bent your rod can often push the cylinder walls out of shape. If that happens the rings on the piston will not seal, making the entire job worthless.

Posted on Sep 10, 2009

Testimonial: "This is the exact type of response I was looking for. Your information was extremely helpful in my understanding of the cause of failure. Thanks."

canwoodjc
  • 3301 Answers

SOURCE: i have a 97 grand

  • In the vast majority of cases, simply cleaning the MAF sensor does the trick. Consult your service manual for it's location if you need help. I find it's best to take it off and spray it with electronics cleaner or brake cleaner. Make sure you are careful not to damage the MAF sensor, and make sure it's dry before reinstalling
  • Inspect all vacuum and PCV hoses, replace if necessary
  • Check for a dirty fuel filter and proper fuel pressure
  • also check the air filter, and any vacuum leaks downstream of the MAF sensor

Posted on Jun 11, 2011

  • 5470 Answers

SOURCE: Code 0300 2000 Mercury Villager

Camshaft position sensor causing random misfire. Stuck EGR valve or clogged EGR ports.

Please comment on my info.

Posted on Mar 30, 2013

mike0862
  • 5428 Answers

SOURCE: 99 grand marquis keeps over heating. I replaced

Are the cooling fans coming on?

Posted on Oct 25, 2014

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1 Answer

2001 Buick Regal keeps stalling and running rough has white smoke coming out of tail pipe


The upper intake plenum is leaking coolant into the cylinder heads. The head gaskets on this motor are awesome. So, chances are it's the upper intake plenum. You can check this, by removing the vacuum hose that runs between the upper plenum and the brake booster. Stick your finger in and try to touch the top of the lower intake manifold. If your finger is wet it the upper plenum. You might as well replace the lower intake gasket while you're performing this work because they are prone to failure also. Use a shop vac to pull any coolant out of the cylinder heads. Get brand new spark plugs because the old ones are probably fouled. Once you get the plenum and gaskets replaced, remove your fuel pump relay and leave the spark plugs out and turn the engine over repeatedly for about 10 seconds to push any excess coolant out of the cylinder heads. Then, put the spark plugs in and turn the engine over for 10 seconds again. This will burn excess fuel as coolant out. Then, replace the fuel pump relay to allow fuel to be pumped into the heads. Car will smoke for a few when it fires up, but will clear out quickly. CHANGE THE OIL! Twice within a week if possible.

Jul 23, 2012 | 2001 Buick Regal

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How to remove air from cooling system 1999 nissan maxima


Remove the negative battery cable from your Nissan Maxima. Wait at least 10 minutes in order to prevent the engine cooling fan from causing any potential harm while your hands are near it. Additionally, the engine must be completely cool in order to safely remove the air intake manifold.

Use a screwdriver to remove the hose clamps around the air intake duct. Gently pull the duct from the rest of the manifold.

Disconnect the accelerator cable, cruise control cable, hoses and electrical connections from the throttle body. Coolant may be lost through some of the hoses, which can be prevented by utilizing hose clamps or plugs. Be prepared with a catch pan underneath the hoses to collect any major spills.

Disconnect the spark plug wires from both the spark plugs and the retainers on the plenum. Unbolt the distributor cap. Use a pen and tape to label each wire with its location so that you can easily return each wire to its exact location once the air intake manifold has been put back in place.

Disconnect the ground strap, which is attached to the upper plenum of the air intake manifold and use a socket wrench to loosen the bolts. There are 11 bolts on the upper intake plenum.

Remove the upper plenum, which should still be attached to the throttle body. While the upper plenum of the Maxima's intake manifold is removed, it is a good idea to clean the mounting surfaces as well as the inside of the manifold with a stiff wire and brake cleaner. Use lint-free mechanics' rags to wipe away carbon buildup.
Removing the Lower Plenum

Drain the cooling system by inserting a catch pan beneath the radiator's drain bolt. Unscrew the drain bolt and hold up a 3/8 hose with a funnel on the end of it to direct the coolant to the catch pan. Open the drain fitting with a pair of pliers and remove the radiator cap.

Remove the radiator hose from the thermostat housing and disconnect the electrical connections from the coolant temperature switch and the coolant temperature sensor. Label these connections with tape and pen as described above for the upper plenum hoses and wires.

Remove the bolts to disconnect the coolant pipes at the transmission's end of the intake manifold.

Loosen the bolts on the lower manifold by turning them in 1/4-turn increments until they can be removed by hand. The manifold may need some gentle nudging to be released from the cylinder heads, but do not pry it loose -- doing so can cause damage to the sealing surfaces, leading to vacuum leaks.

Use a scraper to remove any gasket material and sealant from the outer parts of the manifold and cylinder heads. Clean the mating surfaces with lacquer thinner or acetone so that a new gasket can be applied to the lower manifold.

Jul 08, 2012 | 1999 Nissan Maxima

2 Answers

How to replace a intake plenum gasket


Well basically, you remove the intake plenum and replace the gasket and reinstall the plenum. Here are the steps:

1. Disconnect the negative battery cable from the remote jumper terminal located at the right strut tower.
2. Remove the air inlet resonator and tube.
3. Remove the throttle actuator cables from the throttle arm and bracket.
4. Disconnect Secondary Runner Valve (SRV), Manifold Tuning Valve (MTV), Throttle Position Sensor (TPS), Idle Air Control (IAC) motor electrical connectors.
5. Remove the electrical connector and the Intake Air Temperature/Manifold Absolute Pressure (TMAP) sensor.
6. Disconnect vacuum hoses from the Secondary Runner Valve (SRV) reservoir, Speed Control reservoir, and PCV.
7. Remove right and left intake manifold supports.
8. Remove support brackets at the intake manifold front corners and MTV.
9. Loosen upper fastener attaching throttle body to support bracket.
10. Remove clips attaching EGR tubes to intake manifold.
11. Remove intake manifold bolts and manifold
12. Remove old gaskets, Clean gasket surfaces, and install new gaskets.
13. Reverse steps to reinstall manifold

Jun 16, 2012 | 1999 Chrysler 300M

1 Answer

Intake manafold gasket


If you are just talking about the cost of the gaskets there is kind of an upper (plenum) and a lower intake set. If you just need the plenum gasket they are only about 30 dollars. If you need the entire set there are a couple of option. Just a regular set runs you about 70 (that's both the upper plenum and lower intake manifold but FelPro puts out a great gasket set called "permadry" and the runs about 165 dollars. If you were looking for labor cost it depends on the hourly labor rate of the shop you are using. The labor guide says that if you are replacing both upper & lower it shows 3.4 hours in labor. If it's just the plenum it says 2 hours of labor. Hope this is what you are looking for and by the way I am going by the most common engine found for the Windstar for that year and that engine is a 3.8 liter. If you happen to have the 3.0 the prices and labor hours may be different.

Mar 31, 2012 | 2000 Ford Windstar

1 Answer

How to remove the intake manafold cover to get to the spark plugs


need more info, what size engine? what model need that to send u the correct RnR of the upper plenum

here is the 3.5L version of removal:
  1. Disconnect and isolate the negative battery cable.
  2. Disconnect the Inlet Air Temperature (IAT) sensor electrical connector
  3. Remove the air inlet hose from the throttle body.
  4. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.
    1. Disconnect the PCV hose ,purge hose and power brake booster hose from the upper intake manifold.
    2. Disconnect the electrical connector from the electronic throttle control .
    3. Remove the fasteners from the throttle body and cylinder head and remove the throttle bracket.
    4. Remove the wiper module, strut tower support and EGR tube
    5. Disconnect the electrical connectors from the manifold tuning valve
      1. Remove the fasteners , from the intake manifold support brackets.
      2. Remove the upper intake manifold retaining bolts, insulation foam pad and manifold. Clean all gasket sealing surfaces.

Sep 02, 2010 | 2006 Dodge Charger

1 Answer

Leaking anti freeze from under the air intake hose under tps sensor right where the plenum and upper intake meet it appears


The plastic intake upper plenum is known to warp,causing this leak.I believe too much heat from the nearby EGR port.the solution is more than just a new gasket, an upper intake is usually required.there are aftermarket suppliers,which could save you some money on parts.be sure to check around...good luck

Apr 01, 2010 | 1994 Buick Park Avenue

4 Answers

My 97 oldsmobile cutlass supreme is leaking coolant and over heating, why? I also noticed tht the oil is milky. Please help


The most likely source of your problem is NOT a head gasket or cracked head, but the black plastic plenum or "upper intake manifold". These GM engines tend to melt, crack, or warp the plenum because of the hot EGR tube sticking up through the plastic.

If water is getting into your oil (milky looking), your lower intake manifold gasket is probably cracked. Once the plenum is off the engine, there are only about a dozen bolts holding the lower intake manifold on. When you replace the gasket, it is recommended to use an ALL METAL gasket with rubber seals to prevent this from happening again. The metal gaskets cost about $80 where as the plastic ones that are prone to breaking cost about $45. Better to fix it right once than to do it wrong several times.

Also, if you are still using Dexcool coolant (orangeish), be sure to change it every two years or so as it does bad things to seals when it gets old.

Nov 13, 2009 | 1997 Oldsmobile Cutlass Supreme

1 Answer

Intake manifold gasket / replace


3.8L Engine

NOTE The 3.8L (VIN K) non-supercharged engine uses a two-piece intake manifold consisting of an upper air plenum which mounts the throttle body and a lower intake manifold assembly which houses the fuel injectors. The 3.8L (VIN 1) supercharged engine uses a similar lower intake manifold. The supercharger serves as the upper manifold.
Lower Manifold

NOTE Two bolts which fasten the lower intake manifold to the cylinder head are accessible only after the upper intake manifold is removed. These bolts are located in the right front and left rear corners of the lower intake manifold. Remove the upper intake manifold to service the lower intake.
The 3.8L (VIN 1) supercharged engine uses a manifold similar to the 3.8L (VIN K), but the supercharger serves as the upper manifold.
  1. Disconnect the negative battery cable.
  2. On 3.8L (VIN 1) engines, remove the supercharger assembly. Please see the procedure in this section.
  3. Remove the upper intake manifold using the procedure above.
  4. Remove the EGR outlet pipe from the intake manifold.
  5. Detach the engine coolant temperature sensor wiring harness from the sensor.
  6. Remove the lower intake manifold bolts and carefully lift off the manifold.

To install:


0900c15280269f1b.jpg enlarge_icon.gifenlarge_tooltip.gif Fig. Lower intake manifold bolt torque sequence-3.8L (VIN K) engine
  1. Clean all parts well with degreaser, especially the gasket seal surfaces on the upper and lower manifold pieces and between the lower manifold and the cylinder heads..
  2. Install new gaskets to the cylinder heads and new seals to the engine block. Carefully lower the manifold into place. Apply thread-locking compound to the bolt threads. Make sure to install the two hidden bolts in the lower intake manifold. Hand start all bolts, then torque evenly to 11 ft. lbs. (15 Nm). Follow the toque sequence, starting in the center, then working outwards in a circle.
  3. Install the remaining components in the reverse order of the removal process.

Upper Intake Manifold (Plenum)
  1. Disconnect the negative battery cable.
  2. On 3.8L (VIN 1) engines, remove the supercharger assembly. Please see the procedure in this section.
  3. Tag for identification, then remove the right side spark plug wires.
  4. Disconnect the ignition wires from the fuel rail.
  5. Remove the fuel rail. Please see Section 5.
  6. Remove the cable bracket from the intake manifold.
  7. Remove the throttle body.


NOTE Two bolts which fasten the lower intake manifold to the cylinder head are accessible are accessible only after the upper intake manifold is removed. These bolts are located in the right front and left rear corners of the lower intake manifold.
  1. Remove the upper intake manifold bolts and carefully lift the upper intake manifold from the engine.



0900c15280269f1c.jpg enlarge_icon.gifenlarge_tooltip.gif Fig. Upper intake manifold and bolt torque sequence-3.8L (VIN K) engine
To install:
  1. Clean all parts well with degreaser, especially the gasket seal surfaces on the upper and lower manifold pieces.
  2. Install new gaskets to the cylinder heads and new seals to the engine block. Carefully lower the manifold into place. Make sure to install the two hidden bolts in the lower intake manifold. Hand start all bolts, then torque evenly to 89 inch lbs. (10 Nm). Follow the torque sequence, starting in the center, then working outwards in a circle.
  3. Install the remaining components in the reverse order of the removal process.

Sep 11, 2009 | 1999 Buick Regal

2 Answers

I need to remove the upper intake manifold plenum. All of the obvious bolts are out however the plenum still wont come off. Are there any hiden fasteners inside the plenum?


There are no fasteners inside the plenum, The electrical connection for the injectors is very tight due to a rubber ring gasket the seals the injector assembly to the plenum. Carefully push down on the electrical assmbly while prying up the plenum. You also may have to remove the thermostat and hose. I've done this 3 times on my ladies 96 Yukon.

Jul 11, 2009 | 1996 Chevrolet K1500

2 Answers

Overheatin loosin water and steamin from the back of motor around the intake


You need to have the intake manifold gaskets replaced This will also allow the temp sensor to tell the computer that it has warmed up. Then you can accellerate properly. Good luck Moe

Apr 24, 2009 | 2001 Chevrolet Monte Carlo

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