Question about 2004 Dodge Intrepid

1 Answer

I need to remove the upper intake manifold from my 2004 dodge intrepid 2.7 l engine to replace the water outlet from coolant system. How do I remove and replace the manifold? Will I need a new gasket?

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  • Mike Butler
    Mike Butler May 11, 2010

    Do you mean where thermostat is & bleeder?

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  • 44 Answers

First off, you need to label all of the electrical and vacuum lines connecting to the intake manifold. This will make reassembly much easier. Then, there is a torque sequence to be used during disassembly and reassembly.I need to remove the upper intake manifold from my - 2cf4be0.gif
This image is of the TIGHTENING SEQUENCE. Reverse this to take the manifold off. This is important so that the upper intake manifold is not warped at all, which would decrease the quality of the seal. Be careful during disassembly and reassembly to avoid bending any lines or tubes. If things are in your way, disconnect them rather than pushing them to the side. This will avoid pinching inner linings which cannot be seen visually.

As for the gaskets, (as far as I am aware), Chrysler's (Dodge's) official stance on the manifold gaskets is that they are reusable. However, this is if they ALL look good under close inspection. Any tears, "melting", or other damage means the gaskets should all be replaced. They are not expensive, and I believe they all come as a set including both upper and lower gasket sets. Personally, I would recommend replacing them regardless. This would be a good preventative step to help extend the life of the vehicle. Also be sure to check the cooling line O-rings and replace them as necessary, following the criteria above.

Good luck and I hope this helps, even though I see it is a bit late.

Posted on Aug 02, 2009

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87 dodge diplomat


You should be able to figure it out. It's only two hoses. Think inlet and outlet to the heater core under the dash. The inlet always comes from upper part of engine, where the coolant is the warmest and where it heats up first. The fitting will come from upper part of intake manifold or the cylinder head. then the hose goes to the firewall.
The outlet from the heater core carries coolant back to the engine and almost always to the water pump on the front of the engine. Makes sense, coolant goes back into the water pump and is circulated again back into the engine.

Jun 17, 2017 | Dodge Cars & Trucks

1 Answer

How to replace oil; cooler on this year


  • Service and Repair
Oil Cooler Replacement

Removal Procedure

  1. Raise and support the vehicle. Refer to Vehicle Lifting.
  2. Drain the engine oil and remove the oil filter housing.
89116492

  1. Loosen the oil cooler outlet (1) and the inlet (2) lines from the engine block.
  2. Lower the vehicle.
  3. Remove the intake plenum.
  4. Remove the intake manifold.
89116493

  1. Disconnect the following electrical connectors from the water crossover:
    • The engine coolant temperature sender (2)
    • The engine coolant temperature sensor (4)
84936658

  1. Remove the water crossover bolts (1).
  2. Remove the water crossover upper and lower seals (2).
84942881

  1. Loosen the upper heat shield bolts on the left side of the exhaust manifold.
89116496

  1. Remove the oil cooler outlet line from the engine oil cooler.
  2. Remove the oil cooler inlet line from the engine oil cooler.
84942883

  1. Note the positioning of the 4 seals.
84972057

  1. Position the oil feed and return,lines out of the way and secure with mechanic wire.
  2. Remove the engine oil cooler, inlet and outlet nuts (1).
  3. Remove the engine oil cooler cover bolts (2).
84942883

  1. Remove the engine oil cooler cover.
  2. Remove the engine oil cooler.
  3. Clean all sealing surfaces.
Installation Procedure
84972056

  1. Install the engine oil cooler.
  2. Apply a 2 mm (0.08 inch) bead of RTV silicone sealant, GM P/N 12346240, in the groove around the engine oil cooler cover.
  3. Install the engine oil cooler cover.
Notice: Refer to Fastener Notice in Service Precautions.
84972057

  1. Install the engine oil cooler cover bolts (2). Tighten the engine oil cooler cover bolts to 30 Nm (22 ft. lbs.).
  2. Install the engine oil cooler inlet and outlet nuts (1). Tighten the engine oil cooler inlet and outlet nuts to 20 Nm (15 ft. lbs.).
  3. Reposition the oil feed and return lines.
84942883

  1. Install the oil cooler outlet and install the oil cooler inlet lines to the engine oil cooler. Use 4 new seals.
Tighten the oil feed and return lines to 30 Nm (22 ft. lbs.).
84936658

  1. Install the water crossover:
    • Position the crossover.
    • Install the upper and lower seals (2).
    • Install the water crossover bolts (1). Tighten
Tighten the water crossover bolts to 30 Nm (22 ft. lbs.).
  1. Connect the electrical connectors at the following locations:
    • The engine coolant temperature sensor (4)
    • The engine coolant temperature sender (2)
  1. Install the intake manifold.
  2. Install the intake plenum.
  3. Raise the vehicle.
89116492

  1. Install the oil cooler outlet (1) line to the engine block. Tighten the oil cooler outlet (1) line to 30 Nm (22 ft. lbs.).
  2. Install the oil cooler inlet (2) line to the engine block. Tighten the oil cooler inlet (2) line to 30 Nm (22 ft. lbs.).
  3. Install the oil filter housing to the engine block. Tighten the oil filter housing to 45 Nm (33 ft. lbs.).
  4. Lower the vehicle.

Dec 22, 2014 | 2001 Cadillac Catera

1 Answer

Thermostat on 2005 aviator location


Removal & Installation

Print


4.6L & 5.4L SOHC Engines

  1. Partially drain the engine cooling system to a level below the thermostat.
  2. Disconnect the upper radiator hose from the water outlet adapter.
  3. Remove the power steering reservoir upper mounting bracket.
  4. Remove the bolts and remove the water outlet adapter.
  5. Remove the water thermostat and the O-ring seal. Discard the O-ring seal.
  6. Installation is the reverse of the removal procedure. Tighten the water outlet adapter bolts to 18 ft. lbs. (25 Nm). Tighten the power steering reservoir upper mounting bracket as shown in the accompanying illustration.

    0996b43f80204ea2.jpg enlarge_icon.gifenlarge_tooltip.gif

    Fig. View of the power steering reservoir upper mounting bracket and tightening specifications


    0996b43f80204ea3.jpg enlarge_icon.gifenlarge_tooltip.gif

    Fig. Exploded view of the water outlet adapter and tightening specifications



5.4L & 6.8L Engines

  1. Partially drain the cooling system to a level below the thermostat.
  2. Disconnect the upper radiator hose.
  3. Remove the coolant outlet connection, as follows:
    1. Remove the bolts.
    2. Remove the coolant outlet connection.

  4. Remove the (A) coolant thermostat and the (B) O-ring seal.
  5. Discard the (B) O-ring seal.

    0996b43f80204ef0.jpg enlarge_icon.gifenlarge_tooltip.gif

    Fig. Remove the (A) coolant thermostat and the (B) O-ring seal


To install:

NOTE Thermostat must be installed as illustrated.
  1. Use a new (A) O-ring seal to position the (B) coolant thermostat in the (C) upper intake manifold.

    0996b43f80204ef1.jpg enlarge_icon.gifenlarge_tooltip.gif

    Fig. Use a new (A) O-ring seal to position the (B) coolant thermostat in the (C) upper intake manifold

  2. Install the coolant outlet connection, as follows:
    1. Position the coolant outlet connection on the upper intake manifold.
    2. Install the bolts and tighten to 15-22 ft. lbs. (20-30 Nm).

  3. Connect the upper radiator hose.
  4. Fill the cooling system.

  1. Before servicing the vehicle, refer to the precautions section.
  2. Partially drain the cooling system to a level below the thermostat.
  3. Disconnect the upper radiator hose.
  4. Remove the coolant outlet connection, as follows:
    1. Remove the bolts.
    2. Remove the coolant outlet connection.

  5. Remove the (A) coolant thermostat and the (B) O-ring seal.
  6. Discard the (B) O-ring seal.

    0996b43f80204ef0.jpg enlarge_icon.gifenlarge_tooltip.gif

    Fig. Remove the (A) coolant thermostat and the (B) O-ring seal


To install:

NOTE Thermostat must be installed as illustrated.
  1. Use a new (A) O-ring seal to position the (B) coolant thermostat in the (C) upper intake manifold.

    0996b43f80204ef1.jpg enlarge_icon.gifenlarge_tooltip.gif

    Fig. Use a new (A) O-ring seal to position the (B) coolant thermostat in the (C) upper intake manifold

  2. Install the coolant outlet connection, as follows:
    1. Position the coolant outlet connection on the upper intake manifold.
    2. Install the bolts and tighten to 15-22 ft. lbs. (20-30 Nm).

  3. Connect the upper radiator hose.
  4. Fill the cooling system.


5.4L DOHC Engine

  1. Partially drain the engine cooling system to a level below the thermostat.
  2. Disconnect the upper radiator hose, the heater water inlet hose and the heated PCV inlet hose from the water outlet adapter.

    0996b43f80204ea5.jpg enlarge_icon.gifenlarge_tooltip.gif

    Fig. Disconnect the upper radiator hose, the heater water inlet hose and the heated PCV inlet hose from the water outlet adapter

  3. Remove the water hose connection and thermostat.
  4. Installation is the reverse of the removal procedure. Tighten the mounting bolt to 18 ft. lbs. (25 Nm).

    0996b43f80204ea4.jpg enlarge_icon.gifenlarge_tooltip.gif

    Fig. Exploded view of the thermostat-5.4L DOHC engine

Aug 13, 2012 | 2004 Lincoln Aviator

1 Answer

How does the thermostat fit properly in the housing


selectachapter.gif

Pacifica, 2003-2005
Removal & Installation

Print Here is how to do it,if it does'nt fit right make sure you have the right thermostat.


3.5L Engine


CAUTION Never remove pressure cap with the system hot and under pressure because serious burns from coolant can occur.

  1. Disconnect negative cable from remote jumper terminal.
  2. Drain cooling system.
  3. Disconnect radiator upper hose from thermostat housing.
  4. Remove thermostat housing bolts.
  5. Remove housing, thermostat, and gasket.

    0996b43f80204be2.jpg enlarge_icon.gifenlarge_tooltip.gif

    Fig. View of the coolant outlet connector (1) and thermostat housing (2)-3.5L engine
    View of the coolant outlet connector (1) and thermostat housing (2)-3.5L engine

  6. Clean gasket sealing surfaces.

To install:
  1. Install thermostat and gasket into thermostat housing. For ease of installation, install bolts in housing for thermostat and gasket retention.
  2. Install thermostat and housing to the intake manifold. Tighten the bolts to 105 inch lbs. (12 Nm).
  3. Connect radiator hoses and install hose clamp.
  4. Refill cooling system.
  5. Connect negative cable to remote jumper terminal

May 02, 2012 | 2004 Chrysler Pacifica

1 Answer

Heater fan blows good but only blows cold air. Is it the heater core? The thermostat? How hard are they to replace if i do it myself?


Check the heater core by checking the hotness or coldness of the 2 tubes at the firewall that lead to the heater core.

If both tubes are hot, the heater core is fine. If both tubes are cold, then the heater core is plugged up and will have to be flushed out or replaced.

The thermostat, if stuck open, will delay the heating up of the heater core. It's not hard to replace the thermostat.

Thermostat Removal & Installation 4.2L Engine To Remove:
  1. Before servicing the vehicle refer to the precautions at the beginning of this section.
  2. Remove or disconnect the following:
    • Some of the coolant
    • The upper radiator hose f150_42_thermostat.gif

    • The bolts (A).
    • The water outlet connection (B)
    • The water thermostat and paper gasket assembly (C)
To Install:
NOTE: The water thermostat is indexed and must be installed correctly.
  1. Install or connect the following:
    • The water thermostat
    • The thermostat
    • The water outlet adapter
    • The bolts
      1. Torque to: 80 inch-lbs (9 Nm)
    • The upper radiator hose
    • The coolant
4.6L/5.4L Engines To Remove:
  1. Before servicing the vehicle refer to the precautions at the beginning of this section.
  2. Remove or disconnect the following:
    • Some of the coolant
    • The upper radiator hose f150_46-54_thermostat.gif

    • The bolts (A)
    • The water outlet connection (B)
    • The water thermostat
    • The O-ring (discard)
To Install:
  1. Install or connect the following:
    • A new O-ring to position the water thermostat in the upper intake manifold
    • The water outlet connection onto the upper intake manifold
    • The bolts
      1. Torque to: 18 ft-lbs (25 Nm)
    • The upper radiator hose
    • The coolant
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Jan 28, 2011 | 1997 Ford F150 Regular Cab

1 Answer

How difficult is it to replace a thermostat? on a contour 1999. has the smaller engine


REMOVAL & INSTALLATION

2.0L Engine
See Figures 1 through 6

zjlimited_436.jpg

Fig. 1: Remove the coolant recovery tank hose from the water outlet

zjlimited_437.jpg

Fig. 2: Remove the upper radiator hose from the water outlet

zjlimited_438.jpg

Fig. 3: Remove the three retaining bolts for the water outlet

zjlimited_439.jpg

Fig. 4: Carefully separate the water outlet from the thermostat housing

zjlimited_440.jpg

Fig. 5: Remove the thermostat from the housing

zjlimited_441.jpg

Fig. 6: Make sure you replace the O-ring when installing a new thermostat

  1. Disconnect the negative battery cable.
  2. Drain and recycle the engine coolant.
  3. Remove the air intake resonators.
  4. emove the upper radiator hose and coolant recovery tank hose from the water outlet.
  5. Remove the three retaining bolts from the water outlet and remove the outlet from the thermostat housing.
  6. Remove the thermostat and O-ring from the housing.
To install:
  1. Thoroughly clean the housing and install the thermostat and new O-ring into the housing.
  2. Install the water outlet and tighten the retaining bolts to 71-97 inch lbs. (8-11 Nm).
  3. Install the upper radiator and coolant recovery tank hoses to the water outlet.
  4. Install the air intake resonators.
  5. Connect the negative battery cable.
  6. Fill the cooling system with the proper 50 / 50 mixture and start the vehicle.
  7. Bleed the cooling system and check for leaks.

Hope this helps (remember to rate and comment this asnwer).

Jan 10, 2011 | 1999 Ford Contour

2 Answers

I need to replace the thermostat it is sticking


DRAIN COOLANT LEVEL DOWN BELOW THERMOSTAT.PLACE DRAIN PAN UNDER VECHICLE TO CATCH ANTIFREEZE.WHEN DONE PUT ANTIFREEZE SAFE PLACE FROM KIDS AND ANIMALS.WHEN DONE DRAINING SOME ANTIFREEZE.FOLLOW RADIATOR HOSE TO TOP OF INTAKE TO THERMOSTAT HOUSING. LOOSEN HOSE CLAMP REMOVE RADIATOR HOSE FROM THERMOSTAT HOUSING.THEN LOOSEN HOUSING BOLTS.REMOVE THERMOSTAT HOUSING AND THERMOSTAT.CLEAN BOTH THE THERMOSTAT HOUSING SURFACE AND INTAKE SURFACE YOU CAN USE ACETATE OR BRAKE CLEANER AND SCOTCH BRITES ROLL OF CLEAN PAPER TOWEL. AFTER CLEANING HOUSING AND INTAKE SURFACE MAKE SURFACE CLEAN SMOOTH FROM THE DEBRIS WHEN DONE. TAKE THERMOSTAT PUT GASKET SEALER ON BOTH SIDES OF GASKET PUT GASKET TO THERMOSTAT HOUSING MAKE SURE GASKET AND THERMOSTAT HOUSING HOLES ALIGN CORRECTLY.NOW PLACE NEW THERMOSTAT IN PLACE IN THE INTAKE.MAKE SURE THERMOSTAT SPRING END GOES TOWARD ENGINE FACING DOWN.THEN INSTALL THERMOSTAT HOUSING WITH GASKET TO THE INTAKE.TORQUE THERMOSTAT HOUSING BOLTS TO 20 FT LBS.WAIT 1 HOUR BEFORE POURING ANTIFREEZE BACK IN THE COOLANT SYSTEM GIVE THERMOSTAT GASKET SEALER LITTLE TIME TO CURE.SO YOU WONT HAVE COOLANT LEAKS.NOW IF THERMOSTAT HAS THE LARGE O- RING ON IT YOU DONT HAVE A THERMOSTAT HOUSING GASKET THE THERMOSTAT O- RING IS THE SEAL THAT HOLDS COOLANT INSTEAD OF GASKET.WHEN THERMOSTAT AND HOUSING IN PLACE.INSTALL RADIATOR HOSE TO THERMOSTAT HOUSING TIGHTEN HOSE CLAMP.THEN FILL RADIATOR BACK UP WITH THE COOLANT YOU DRAIN OUT.START VECHICLE UP. THEN CHECK FOR LEAKS.

Nov 03, 2010 | 1992 Buick LeSabre

1 Answer

I need to change the thermostat


REMOVAL
  1. Remove upper intake manifold.
  2. Partially drain cooling system below the thermostat level.
  3. Remove upper radiator hose from outlet connector.
  4. Remove coolant recovery system hose from outlet connector.
  5. Remove coolant outlet connector bolts.
  6. Remove thermostat assembly, and clean sealing surfaces.
INSTALLATION

25a9b05.gif
  1. Place the new thermostat assembly into the coolant outlet connector, aligning air bleed with the location notch on outlet connector.
  2. Install coolant outlet connector with thermostat in position onto thermostat housing. Tighten bolts to 12.5 Nm (110 inch lbs.).
  3. Install upper radiator hose.
  4. Connect the coolant recovery system hose.
  5. Install upper intake manifold.
  6. Fill cooling system.
  7. see thermostat mounting are below
a4322e5.gif

Oct 19, 2010 | 2002 Chrysler PT Cruiser

1 Answer

How do u change a thermostat in a 99 buick la sabre, there is only cold heat coming out of the heater


The thermostat is used to control the flow of engine coolant. When the engine is cold, the thermostat is closed to prevent coolant from circulating through the engine. As the engine begins to warm up, the thermostat opens to allow the coolant to flow through the radiator and cool the engine to its normal operating temperature. Fuel economy and engine durability is increased when operated at normal operating temperature.


REMOVAL & INSTALLATION
CAUTION Never open, service or drain the radiator or cooling system when hot; the system is under pressure and will release scalding hot coolant and steam which can cause severe burns and other bodily harm. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.
  1. If necessary, unfasten the retainer and remove the upper engine cover.
  2. Disconnect the negative battery cable.
  3. Remove the air cleaner and duct assembly.
  4. Partially drain the engine cooling system, into a suitable container, to a level below the thermostat.
  5. Disconnect the upper radiator hose from the water outlet.
  1. If necessary, detach the electrical connections from the throttle body assembly.
  2. Unfasten the water outlet attaching bolts, then remove the water outlet.
  1. Remove the thermostat. Remove and discard the gasket.
  1. Thoroughly clean the manifold water inlet and water outlet mating surfaces. Inspect the water outlet for corrosion or other damage, and replace if necessary.
2f45efd.jpg

Fig. 8: Exploded view of the thermostat and housing assembly - 3.8L (VIN C) engine

018cedc.jpg

Fig. 9: Thermostat and water outlet mounting - 3.8L (VIN L) engine shown

e1a13ea.jpg

Fig. 10: Exploded view of the thermostat, gasket and housing assembly - 1997 vehicle shown

To install:

  1. Position the thermostat into the intake manifold with a new gasket.
  2. Install the water outlet to the intake manifold with RTV sealer. Tighten the attaching bolts to 20 ft. lbs. (27 Nm).
  3. Connect the radiator hose to the water outlet housing.
  4. If necessary, attach the electrical connections to the throttle body assembly.
  5. Install the air cleaner assembly, then connect the negative battery cable.
  6. Refill the engine with the specified type and amount of engine coolant. Start the engine and check for coolant leaks.

I hope this helps; remember to rate this post. Good luck.

Oct 05, 2010 | 1999 Buick LeSabre

2 Answers

Need to replace the intake manifold


3.8L Engine (most common) Upper Intake Manifold To Remove:
  1. Drain the cooling system.
  2. Remove or disconnect the following:
    • Negative battery cable.
    • Fuel injector sight shield.
    • Air cleaner intake duct.
    • Right spark plug wires from the ignition control module and reposition.
  3. Relieve the fuel pressure.
  4. Remove or disconnect the following:
    • Fuel rail assembly.
    • Brake booster hose from the vacuum source manifold in the upper intake manifold.
    • Exhaust Gas Recirculation Valve (EGR) wiring harness heat shield nut, bolt and the EGR heat shield.
    • Throttle body support bracket upper bolt.
  5. Disconnect the electrical connectors from the following:
    • EVAP purge solenoid
    • Throttle Position (T/P) sensor
    • Idle Air Control (IAC) valve
    • Manifold Absolute Pressure (MAP) sensor
    • Mass Air Flow (MAF) sensor
    • EVAP purge solenoid vacuum line from the throttle body.
    • Accelerator and the cruise control cables with the bracket from the throttle body.
  6. Remove or disconnect the following:
    • Upper intake manifold bolts and stud.
    • Clean the upper intake manifold bolt threads.
  7. Remove or disconnect the following:
    • Upper intake manifold by lifting the back of the intake and sliding the manifold forward from the throttle body support bracket.
    • Upper-to-lower intake manifold carrier gasket from the upper intake manifold.
  8. If the upper intake manifold is being replaced, remove the following:
    • Throttle body assembly.
    • Manifold Absolute Pressure (MAP) sensor.
    • Positive Crankcase Ventilation (PCV) valve.
    • Vacuum source manifold.
Upper intake manifold bolt torque sequence (3.8L engine) gm-03-38-530.gif

To Install:
  1. If the manifold was replaced, install or connect the following:
    • Vacuum source manifold.
    • Positive Crankcase Ventilation (PCV) valve.
    • Manifold Absolute Pressure (MAP) sensor.
    • Throttle body assembly.
    • Upper-to-lower intake manifold carrier gasket to the upper intake manifold.
  2. Carefully place the upper intake manifold onto the lower intake manifold. Ensure that the alignment pins in the upper intake manifold align with the holes in the lower intake manifold. NOTE: Apply thread lock compound, to the bolt threads before assembly.
  3. Install or connect the following:
    • Upper intake manifold. Tighten the upper intake manifold bolts in sequence to 89 in lbs (10 Nm)
    • Accelerator and the cruise control cables with the bracket to the throttle body.
    • EVAP purge solenoid vacuum line to the throttle body.
  4. Connect the electrical connectors to the following:
    • Mass Air Flow (MAF) sensor
    • Manifold Absolute Pressure (MAP) sensor
    • Idle Air Control (IAC) valve
    • Throttle Position (T/P) sensor
    • EVAP purge solenoid
  5. Install or connect the following:
    • Throttle body upper support bracket bolt. Tighten the bolt to 89 in lbs (10 Nm)
    • EGR valve wiring harness heat shield, nut and the bolt. Tighten the nut and the bolt to 89 in lbs (10 Nm)
    • Brake booster hose to the vacuum source manifold.
    • Fuel rail assembly.
    • Right spark plug wires.
    • Air cleaner intake duct.
    • Fuel injector sight shield.
  6. Connect the negative battery cable.
  7. Fill the cooling system.
  8. Inspect for fluid or vacuum leaks.
Lower Intake Manifold (W/O Supercharger) To Remove:
  1. Remove or disconnect the following:
    • Upper intake manifold.
    • Generator brace.
    • Drive belt tensioner with the mounting bracket and the heater water bypass inlet pipe.
    • Exhaust gas recirculation EGR outlet pipe bolt from the lower intake manifold.
    • Radiator inlet hose from the water outlet housing.
    • ECT sensor electrical connector.
    • Right upper engine mount strut bracket.
    • Generator brace bracket bolts.
    • Generator brace bracket.
    • Lower intake manifold bolts.
    • Lower intake manifold.
    • Lower intake manifold seals.
    • Lower intake manifold gaskets.
  2. If replacing the lower intake manifold, Remove or disconnect:
    • Water outlet housing bolt and stud
    • Water outlet housing
    • Gasket and the thermostat.
    • ECT sensor.
  3. Inspect the flatness of inlet flanges.
  4. Clean the intake manifold mating surfaces.
  5. Clean the intake manifold bolts and bolt holes of adhesive compound.
To Install:
  1. If removed, install the ECT sensor.
    • Tighten the ECT sensor to 18 ft. lbs. (25 Nm)
  2. If removed, install the thermostat, the gasket, and the water outlet housing.
  3. If removed, install the water outlet housing bolt and the stud.
    • Tighten the bolt and stud to 20 ft. lbs. (27 Nm)
  4. Install or connect the following:
    • Lower intake manifold gaskets. NOTE: Apply sealer GM P/N 12346286 (Canadian P/N 10953472) or equivalent to the ends of the intake manifold seals.
    • Lower intake manifold seals.
    • Lower intake manifold.
    • Lower intake manifold bolts.
    NOTE: Apply thread lock compound GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the two hidden bolts and ensure they are installed.
  5. Tighten the lower intake manifold bolts in sequence to 11 ft. lbs. (15 Nm) gmpc_v6_5.gif

  6. Install or connect the following:
    • Generator brace bracket.
    • Generator brace bracket bolts. Tighten the bolts to 37 ft. lbs. (50 Nm)
    • Right upper engine mount strut bracket.
    • ECT sensor electrical connector.
    • Radiator inlet hose to the water outlet housing.
    • EGR outlet pipe to the lower intake manifold.
    • EGR outlet pipe bolt to the lower intake manifold. Tighten the bolt to 21 ft. lbs. (29 Nm)
    • Drive belt tensioner.
    • Generator brace.
    • Upper intake manifold.
  7. Inspect for leaks.
Lower Intake Manifold (W/ Supercharger) To Remove:
  1. Disconnect the negative battery cable.
  2. Drain the cooling system.
  3. Remove the supercharger.
  4. Remove the thermostat housing.
  5. Remove the EGR pipe at the intake manifold.
  6. Disconnect the electrical connection at the temperature sensor.
  7. Remove the intake manifold and gaskets.
NOTE: The coolant bypass tube will release from the intake manifold when the manifold is removed.
To Install:
  1. Clean the gasket sealing surfaces.
  2. Install the intake manifold gaskets.
  3. Align the coolant bypass tube with the opening in the intake manifold and install the manifold. Tighten the bolts to 11 lb ft (15 Nm).
  4. Install the electrical connector to the temperature sensor.
  5. Install the EGR pipe to the intake manifold.
  6. Install the thermostat housing.
  7. Install the supercharger.
  8. Fill the cooling system.
  9. Connect the negative battery cable.

Aug 05, 2010 | 1997 Pontiac Grand Prix

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