Question about 2001 Dodge Intrepid

1 Answer

SWAPPED 2.7 NON EGR INTO 2.7 EGR CAR SWITCHED INTAKE EXHAUST MANIFOLD AND WIRING HARNESS EGR SYSTEM NO START THE FLYWHEEL IS DIFFERENT BETWEEN THE TWO AND THE NON EGR WIRING HARNESS WONT PLUG INTO EGR COMPUTER WHAT OPIONS DO I HAVE?CAN YOU REFLASH COMPUTER TO READ NEW FLYWHEEL SPACING? REMOVE FLYWHEEL AND CAM SPROCKET?

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  • restomark Jul 10, 2010

    I did try unplugging cam sensor still wont start

  • restomark Jul 11, 2010

    both engines are 01. I left flywheel on didnt change anything except harness intake right exhaust manifold and egr system so the cam and crank should be in sync.

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  • Master
  • 4,669 Answers

Does it start if you unplug the cam sensor? I'll bet it does. If yes then you will have to replace the cam sensor ring on the cam pulley.

Posted on Jul 10, 2010

  • Clint Smock
    Clint Smock Jul 10, 2010

    You took the flywheel off the original engine and bolted it on the new engine? You are working on a 01 intrepid right? Do you know what year the new engine is and what model it is out of? Do you still have some plugs that won't connect or did you resolve that problem by changing the harness.

  • Clint Smock
    Clint Smock Jul 11, 2010

    If both engines are the same year the flywheel and cam pick up should be the same. Check for power on the coils and pulsing ground. Or see if it will start if you spray carb cleaner into it. You might just have a bad crank sensor.

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Torque setting for a 1998 ford taurus 3.0 intake manifold


TORQUE SPECIFICATIONSDescriptionNmLb-FtLb-InEngine Air Cleaner Tube Clamps1.6-2.2-14-19Engine Control Sensor Wiring Through Bolts2.5-3.5-23-30Generator to Bracket Bolt3727-Generator to Cylinder Head Bolt4835-Generator Brace to Upper Intake Manifold Bolts and Nut12-209-14-Intake Manifold Support to Throttle Body8-12-71-106Intake Manifold Support to RH Cylinder Head40-5530-40-Degas Tube to Upper Intake Manifold Bolts8-12-71-106Camshaft Sprocket to Camshaft Bolt50-7037-51-Camshaft Thrust Plate Bolt10-88Coil and Bracket to Cylinder Head Bolt40-5530-40-Connecting Rod Nut31-3923-28-Crankshaft Damper to Crankshaft Bolt125-16593-121-Crankshaft Pulley to Damper (4 Bolts)40-6030-44-Cylinder Head Retaining Bolt(1)(1)-Accelerator Cable Shield Bolts1.4-13Camshaft Position Sensor Housing Retaining Bolt2417-EGR Tube Connector to Exhaust Manifold40-4730-34-EGR Valve to Upper Intake Manifold Bolt20-3015-22-EGR Tube to EGR Valve and Exhaust Manifold35-6526-47-Exhaust Manifold Bolt/Stud20-2515-18-Flywheel to Crankshaft Bolt73-8754-64-Fuel Injection Supply Manifold to Intake Manifold8-12-71-106Throttle Cable Bracket1713-Dual Converter Y Pipe to Exhaust Manifolds34-4725-34-Crankshaft Position Sensor Bolts5-7-45-61Intake Manifold to Cylinder Head Bolt (5)(2)(2)-Main Bearing Cap Bolt75-8556-62-Oil Drain Plug11-169-11-Oil Filter Insert to Cylinder Block27-4020-29-Oil Filter to Oil Filter Adapter(3)(3)-Oil Galley and Cooling Jacket Plugs2014-Oil Level Indicator Tube to Exhaust Manifold Nut16-2012-14-Engine to Transaxle/Torque Converter Assembly Bolts40-6030-44-Torque Converter Nuts27-4620-33-Transmission Range Sensor Nut16-2212-16-Front Sub-Frame-to-Body Bolts77-10357-75-Oil Pressure Sensor16-2212-16-Oil Pump to Cylinder Block Bolt40-5530-40-Power Steering Bracket to Cylinder Head Bolt40-5530-40-Valve Cover to Cylinder Head Bolts/Studs (5)10-14-89-123Right Exhaust Manifold Heat Shield Retaining Bolts8-12-71-106Rocker Arm Seat to Cylinder Head Bolt(4)(4)-Water Outlet Connection to Intake Manifold Bolt10-14-89-123Upper Intake Manifold to Lower Intake Manifold Bolt/Stud20-3015-22-Engine Front Cover to Cylinder Block Bolt (No. 1-10)2518-Engine Front Cover to Cylinder Block Bolt (No. 11-15)10-88Water Pump Pulley to Hub (4 Bolts)20-3015-22-Water Pump to Front Cover Bolt8-12-71-106Wiring Retainer Bracket Nut20-3015-22-Valve Tappet Guide Plate to Cylinder Block10-14-89-123Ignition Coil Bracket40-5530-40-Oil Pan to Cylinder Block Bolt10-14-89-123Water Bypass Tube Nut20-3015-22-Crankshaft Pulley Bolts40-5530-40-


  1. Tighten in four steps (refer to illustration in Cylinder Head Installation for tightening sequence):
    • Tighten in sequence to 70-90 Nm (52-66 Lb-Ft)
    • Then back off all bolts 360 degrees
    • Tighten in sequence to 45-55 Nm (34-40 Lb-Ft)
    • Tighten in sequence to 85-99 Nm (63-73 Lb-Ft)
  2. Tighten in two steps
    • 20-30 Nm (15-22 Lb-Ft)
    • 26-32 Nm (20-23 Lb-Ft)
  3. Advance 3/4 to 1 turn after gasket contacts sealing surface or tighten to 13-15 Nm (10-11 Lb-Ft).
  4. Tighten in two steps:
    • 7-15 Nm (6-11 Lb-Ft)
    • 26-38 Nm (20-28 Lb-Ft)
  5. Refer to illustration in the Cylinder Head Installation procedure for tightening sequence.

Jan 10, 2012 | 1998 Ford Taurus

1 Answer

I need written instructions for installing an EGR Valve on a 96 Ford Exploer Eddie Bauer V6 4.0 engine. Trying to pass emission inspection.


zjlimited_986.jpg

Fig. 4: Exploded view of the EGR system and related components for the 4.0L engine (click over pic for zoom)

REMOVAL & INSTALLATION

PFE/DPFE Sensor
This component is found on all engines, and is also referred to as the backpressure transducer.
  1. Disconnect the negative battery cable.
  2. Detach and label the wiring harness connector from the PFE/DPFE sensor.
  3. Disconnect all of the hoses from the sensor.
  4. Remove the mounting nuts, then separate the sensor from the mounting bracket.
  5. If necessary, remove the EVR solenoid and the PFE/DPFE mounting bracket from the upper intake manifold.
To install:
  1. If removed, install the EVR solenoid and mounting bracket onto the upper intake manifold.
  2. If applicable, install the EGR tube heat shield.
  3. Position the PFE/DPFE sensor on the mounting bracket, then install and tighten the mounting nuts until snug.
  4. Attach all necessary hoses and wiring to the sensor.
  5. Connect the negative battery cable.

EGR Vacuum Regulator (EVR) Solenoid
The EVR solenoid is mounted either on the same bracket as the PFE/DPFE sensor, attached to the upper intake manifold, or near the EGR valve on its own bracket.
  1. Disconnect the negative battery cable.
  2. Label and detach the wiring harness connector from the EVR solenoid.
  3. Detach the main emission vacuum control connector from the solenoid.
  4. Remove the retaining nuts, then separate the solenoid from the mounting bracket.
To install:
  1. Position the solenoid on its mounting bracket and install the retaining nuts.
  2. Attach the main emission vacuum control connector and the wiring harness connector to the EVR solenoid.
  3. Connect the negative battery cable.

EGR Valve
See Figures 6 and 7
  1. Disconnect the negative battery cable.
  2. If necessary, remove the air inlet tube from the throttle body and air cleaner housing.
  3. Label and detach all vacuum hoses from the EGR valve.
  4. Label and detach any electrical wiring harness connectors from the EGR valve.
  5. Disconnect the EGR valve-to-exhaust manifold tube from the EGR valve.
  6. Remove the EGR valve mounting fasteners, then separate the valve from the upper intake manifold.
  7. Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold.
zjlimited_987.jpg

Fig. 6: Cutaway view of a base entry type EGR valve

zjlimited_988.jpg

Fig. 7: Cutaway view of a side entry type EGR valve

To install:

  1. Install the EGR valve, along with a new gasket, on the upper intake manifold, then install and tighten the mounting bolts to 4-22 ft. lbs. (20-30 Nm) on 3.8L engines, or to 106-49 inch lbs. (1-18 Nm) on 5.0L engines.
  2. Connect the EGR valve-to-exhaust manifold tube to the valve, then tighten the tube nut to 30 ft. lbs. (41 Nm).
  3. Connect all wiring or hoses to the EGR valve.
  4. Install the air inlet tube.
  5. Connect the negative battery cable.


Hope this helps, good luck (remember to rate this comments).

Apr 06, 2011 | Ford Explorer Cars & Trucks

1 Answer

Erroe code po405 on my car


Hello.
The error code PO405 = EGR, ( Exhaust Gas Recirculation ), sensor A circuit low input.

What the EGR does;
EGR = Exhaust Gas Recirculation system
Recycles small amounts of exhaust gas from exhaust system, 8 to 10 %, and mixes it with intake manifold air going into the combustion chambers. The addition of this inert, or non-combustable exhaust gas limits the peak combustion temperatures to a range that is below 2,500 degrees F, where the formation of nitrogen oxide, ( NOx ), is known to occur.

Here's a picture of an EGR valve to help you locate yoursem1cl_1.jpg
You may find that you just have a lose hose, or you may have a small vacuum leak.

I hope this helps you.
Donnie

Mar 09, 2011 | Ford Focus Cars & Trucks

1 Answer

Where is the egr valve on the 2006 ford explorer


i hope that this could help you the EGR valve is the item #7

ganyapr_0.jpg

Item Part Number Description 1 - EGR system module electrical connector (part of 12B637) 2 9E498 Engine vacuum harness 3 - EGR system module-to-exhaust manifold tube upper fitting (part of 9E469) 4 - EGR system module-to-exhaust manifold tube lower fitting (part of 9E469) 5 9E469 EGR system module-to-exhaust manifold tube 6 W506024 EGR system module bolts (2 required) 7 9D475 EGR system module 8 9D476 EGR system module gasket

Feb 13, 2011 | 2006 Ford Explorer

1 Answer

How to replace head gasket on 4 cylander


2.6L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Drain the cooling system.
  3. Relieve the fuel system pressure.
  4. Remove or disconnect the following:
    • Negative battery cable
    • Hood
    • Accessory drive belts
    • Accelerator cable
    • Positive Crankcase Ventilation (PCV) valve and hose
    • Air intake duct
    • Fuel pressure regulator vacuum line
    • Canister hose
    • Brake booster vacuum line
    • Engine wiring harness connectors at right wheel housing
    • Ground cable connector at the intake manifold, starter and firewall
    • Heated Oxygen (HO2S) sensor connector
    • Alternator wiring connectors
    • Oil pressure switch connector
    • Starter motor harness connectors
    • Ignition coil connector
    • Spark plug wires
    • Distributor
    • Exhaust front pipe
    • Exhaust Gas Recirculation (EGR) gas temperature sensor connector
    • Air pump
    • EGR pipe
    • Heat shield
    • Exhaust manifold
    • Throttle Position (TP) switch connector
    • Cooling fan
    • Water pump pulley
    • Power steering pump
    • Intake manifold
    • Crankshaft pulley
    • Front cover
    • Timing belt. Refer to the Timing Belt unit repair section.
    • Valve cover
    • Rocker arms
    • Camshaft
    • Cylinder head
Cylinder head bolt loosening sequence - 2.6L engine

tecnovative_96.gif
  1. To install:
  2. NOTE: Refer to Section 1 of this manual for the cylinder head torque sequence illustration. The illustration is located after the Torque Specification Chart.
  3. NOTE: Lubricate the cylinder head bolts with clean engine oil for assembly.
  4. Install the cylinder head with a new gasket. Tighten the bolts in sequence as follows:
  5. Step 1: 58 ft. lbs. (75 Nm)
  6. Step 2: 72 ft. lbs. (98 Nm)
    1. Install or connect the following:
    2. Camshaft
    • Rocker arms
    • Valve cover
    • Timing belt
    • Front cover
    • Crankshaft pulley. Tighten the bolt to 87 ft. lbs. (128 Nm).
    • Intake manifold
    • Power steering pump
    • Water pump pulley
    • Cooling fan
    • TP switch connector
    • Exhaust manifold
    • Heat shield
    • EGR pipe
    • Air pump
    • EGR gas temperature sensor connector
    • Exhaust front pipe
    • Distributor
    • Spark plug wires
    • Ignition coil connector
    • Starter motor harness connectors
    • Oil pressure switch connector
    • Alternator wiring connectors
    • HO2S sensor connector
    • Ground cable connector at the intake manifold, starter and firewall
    • Engine wiring harness connectors at right wheel housing
    • Brake booster vacuum line
    • Canister hose
    • Fuel pressure regulator vacuum line
    • Air intake duct
    • PCV valve and hose
    • Accelerator cable
    • Accessory drive belts
    • Hood
    • Negative battery cable
    1. Fill the cooling system.
    2. Start the engine and check for leaks.

    tecnovative_65.jpg

    Feb 05, 2011 | 1997 Isuzu Rodeo

    1 Answer

    97 Nissan Maxima OBDll code p1400. I replaced the egr valve the code still flips any suggestions would be greatly appreciated


    The code p1400, is for an egrc solenoid valve, not the egr valve, they are 2 seperate items

    exhaust-gas recirculation (EGR): An emissions-control system that reduces an engine's production of oxides of nitrogen by diluting the air/fuel mixture with exhaust gas so that peak combustion temperatures in the cylinders are lowered.

    exhaust-gas recirculation valve (EGR valve): A valve, generally vacuum operated, to regulate the exhaust gas flow into the intake manifold.

    EGR control solenoid (EGRC): receives ported and manifold vacuum, an EGR temperature sensor and a control backpressure transducer valve. THE operation of the system is controlled by the PCM which operates the EGRC solenoid. The manifold vacuum system utilizes a vacuum tap in the air intake system positioned after the throttle valve. The ported vacuum control system uses a vacuum tap in the throttle body which is exposed to an increasing percentage of manifold vacuum as the throttle valve is opened during acceleration. The backpressure transducer valve monitors the exhaust backpressure as the engine rpm increases or decreases to aid in controlling the amount of the EGR vacuum signal. The EGR temperature sensor is used to inform the PCM of temperature changes in the EGR passage way. This helps the PCM determine the EGR on/off time.

    that should help on what they all do.

    now by knowing all of that i highly doubt that the control solenoid could cause the problem, and if it was that then u probably have a PCM problem not the solenoid or both.P01400 generally means that the ECM is not seeing the correct voltage drop when it grounds the EGRC valve located between the banks of CLY'S near the top Radiator hose location the EGRC solenoid valve turns vacuum on to the EGR circuit or vents. With a OHM meter unplug the EGRC valve and measure resistance at the two pins. Most likely your car has a bad EGRC valve or a BAD wire to it from the engine control module. Valve Nissan Dealership would cost around $45 labor to diagnosis and replace $150. Make sure proper diagnosis is performed check the engine wiring harness with a stop lamp light bulb hooked to the EGRC connector to see if it lights up when driving. That way you know the circuit is ok. A engine harness with a open circuit is a bad surprise after spending $200 for the valve. Good Luck

    Oct 08, 2010 | 1997 Nissan Maxima

    1 Answer

    Picture of egr valve and were it is located


    dffc43b.jpg

    Fig. 11: EGR valve and component mounting-3.0L engine


    da251ab.jpg

    Fig. 12: EGR valve and component mounting-3.8L engine

    Removal:
    1. Disconnect the negative battery cable.
    2. If necessary, remove the air inlet tube from the throttle body and air cleaner housing.
    3. Label and detach all vacuum hoses from the EGR valve.
    4. Label and detach any electrical wiring harness connectors from the EGR valve.
    5. Disconnect the EGR valve-to-exhaust manifold tube from the EGR valve.
    6. Remove the EGR valve mounting fasteners, then separate the valve from the upper intake manifold.
    7. Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold.
    To install:
    1. Install the EGR valve, along with a new gasket, on the upper intake manifold, then install and tighten the mounting bolts to 15-22 ft. lbs. (20-30 Nm) on 3.8L engines, or to 106-159 inch lbs. (12-18 Nm) on 5.0L engines.
    2. Connect the EGR valve-to-exhaust manifold tube to the valve, then tighten the tube nut to 30 ft. lbs. (41 Nm).
    3. Connect all wiring or hoses to the EGR valve.
    4. Install the air inlet tube.
    5. Connect the negative battery cable.

    Hope this helps (remember comment and rated this).

    Jul 27, 2010 | 1995 Ford Windstar

    2 Answers

    Egr valve cleaning


    Usually the EGR valve problems show the fault code P0400 - Exhaust Gas Recirculation Flow Malfunction

    What does that mean?
    The exhaust gas recirculation (EGR) valve is vacuum controlled valve that regulates the amount of exhaust gases that re-enter the cylinders. The powertrain control module (PCM) determines how much based on engine load, temp, and other conditions. If the PCM detects that the amount of exhaust gases entering the cylinder were insufficient or non-existent, this code is set.


    Symptoms
    No symptoms will likely be noticed by the driver other than the MIL (malfunction indicator lamp). However, non visible symptoms will be increased combustion temperature and increased Nox emissions.


    Causes
    A code P0400 may mean that one or more of the following has happened:
    * Plugged EGR passage which restricts the flow of exhaust gasses
    * Faulty EGR solenoid
    * Faulty EGR solenoid wiring/harness
    * Vacuum lines damaged/disconnected to the EGR valve solenoid or to the EGR valve
    * Faulty EGR valve


    Possible Solutions
    Since EGR valve designs are different, no one test will suffice:
    * Using a scan tool, operate the EGR valve with the engine running. If the engine stumbles, the problem was likely intermittent wiring problem or intermittent blockage problem
    * If engine doesn't stumble, operate the EGR valve manually, if possible. If engine doesn't stumble and die, the ports are likely plugged. Removal of valve and cleaning of all ports will be required
    * Checking of solenoid can only usually be done with a scan tool, because most solenoids operate with a duty cycle of voltage, rather than constant voltage
    * Check all vacuum lines, hoses, etc for any damage
    * Visually inspect the solenoid harness and the solenoid for damage
    * Replace EGR valve


    FOr price about this part, check this links:
    - cpwstore.carpartswholesale
    - autopartswarehouse

    Hope this helped (remember comment and rated this).

    May 08, 2010 | 1998 Suzuki Esteem

    1 Answer

    How do you take off a intake manifold


    This is for the 4.6L motor...I'll post for the 5.0L and 5.8L....you didn't post your engine size so please pick the applicable motor:

    4.6L Engine
    CAUTION Fuel injection systems remain under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

    1. If equipped with air suspension, the air suspension switch, located on the right-hand side of the luggage compartment, must be turned to the OFF position before raising the vehicle.
    2. Disconnect the negative battery cable.
    3. Drain the engine cooling system.
    4. Relieve the fuel system pressure as follows:
      1. Remove the fuel tank fill cap to relieve the pressure in the fuel tank.
      2. Remove the cap from the Schrader valve located on the fuel injection supply manifold.
      3. Attach Fuel Pressure Gauge T80L-9974-B or equivalent, to the Schrader valve and drain the fuel through the drain tube into a suitable container.
      4. After the fuel system pressure is relieved, remove the fuel pressure gauge and install the cap on the Schrader valve. Secure the fuel tank fill cap.
    5. Disconnect the fuel supply and return lines.
    6. Remove the windshield wiper governor (module).
    7. Remove the engine air cleaner outlet tube.
    8. Release the drive belt tensioner and remove the accessory drive belt.
    9. Tag and disconnect the ignition wires from the spark plugs. Disconnect the ignition wire brackets from the cylinder head cover studs.
    10. Disconnect the wiring from both ignition coils and the Camshaft Position (CMP) sensor. Tag and disconnect all ignition wires from both ignition coils. Remove 2 bolts retaining the ignition wire bracket to the ignition coil brackets and remove the ignition wire assembly.
    11. Disconnect the alternator wiring harness from the junction block at the fender apron and alternator. Remove the bolts retaining the alternator brace to the intake manifold and the alternator to the cylinder block and remove the alternator.
    12. Raise and safely support the vehicle.
    13. Disconnect the oil pressure sensor and power steering control valve actuator wiring and position the wiring harness out of the way.
    14. Disconnect the EGR valve to exhaust manifold tube from the right-hand exhaust manifold.
    15. Lower the vehicle.
    16. Remove and detach the engine/transmission harness connector from the retaining bracket on the power brake booster.
    17. Detach the A/C compressor clutch, Crankshaft Position (CKP) sensor and the canister purge solenoid wiring connectors.
    18. Remove the PCV valve from the cylinder head cover and disconnect the canister purge vent hose from the PCV valve.
    19. Disconnect the accelerator and cruise control cables from the throttle body. Remove the accelerator cable bracket from the intake manifold and position out of the way.
    20. Disconnect the vacuum hose from the throttle body adapter port.
    21. Disconnect both Heated Oxygen Sensors (HO2S) and the heater water hose.
    22. Remove 2 bolts retaining the thermostat housing to the intake manifold and position the upper hose and thermostat housing out of the way.
    The 2 thermostat housing bolts are also used to retain the intake manifold.
    1. Remove 9 bolts retaining the intake manifold to the cylinder heads and remove the intake manifold. Remove and discard the gaskets.
    2. If replacing the intake manifold, swap over the necessary parts.
    To install:
    1. Clean all gasket mating surfaces.
    2. Position new intake manifold gaskets on the cylinder heads. Make sure the alignment tabs on the gaskets are aligned with the holes in the cylinder heads.
    3. Install the intake manifold and 9 retaining bolts. Hand tighten the right-rear bolt (viewed from the front of the engine) before final tightening, then torque the bolts, in sequence, to 15-22 ft. lbs. (20-30 Nm).
    4. Inspect and if necessary, replace the O-ring seal on the thermostat housing. Position the housing and upper hose and install 2 retaining bolts. Torque to 15-22 ft. lbs. (20-30 Nm).
    5. Reconnect the heater water hose.
    6. Reconnect both HO2S wiring connectors.
    7. Reconnect the vacuum hose to the throttle body adapter vacuum port.
    8. Install the accelerator cable bracket on the intake manifold and connect the accelerator and cruise control cables to the throttle body.
    9. Install the PCV valve in the cylinder head cover and connect the canister purge solenoid vent hose. Reconnect the A/C compressor clutch, CKP sensor and canister purge solenoid wiring connectors.
    10. Reconnect the engine/transmission harness connector. Install the connector on the retaining bracket on the power brake booster.
    11. Raise and safely support the vehicle.
    12. Reconnect the EGR valve to exhaust manifold tube to the right-hand exhaust manifold. Torque the tube nut to 26-33 ft. lbs. (35-45 Nm).
    13. Reconnect the power steering control valve actuator and the oil pressure sensor wiring connectors.
    14. Lower the vehicle.
    15. Position the alternator and install 2 retaining bolts. Torque to 15-22 ft. lbs. (20-30 Nm). Install 2 bolts retaining the alternator brace to the intake manifold and torque to 71-106 inch lbs. (8-12 Nm).
    16. Reconnect the alternator wiring harness to the alternator, right-hand fender apron and junction block.
    17. Position the ignition wire assembly on the engine and install 2 bolts retaining the ignition wire bracket to the ignition coil brackets. Torque the bolts to 71-106 inch lbs. (8-12 Nm).
    18. Reconnect the ignition wires to the ignition coils in their proper positions. Reconnect the ignition wires to the spark plugs.
    19. Reconnect the ignition wire brackets on the cylinder head cover studs. Reconnect the wiring connectors to both ignition coils and the CMP sensor.
    20. Install the accessory drive belt.
    21. Install the engine air cleaner outlet tube.
    22. Install the windshield wiper governor.
    23. Reconnect the fuel supply and return lines.
    24. Fill and bleed the engine cooling system.
    25. Reconnect the negative battery cable.
    26. If equipped with air suspension, turn the air suspension switch to the ON position.
    27. Start the engine and check for leaks.
    28. Road test the vehicle and check for proper operation.
    4dc9694.gif
    4.6L engine intake manifold torque sequence—1996-98 Models

    Nov 30, 2009 | 1997 Mercury Grand Marquis

    1 Answer

    Intake manifold gasket


    prev.gif next.gif Intake Manifold REMOVAL & INSTALLATION 1.9L SOHC Engine
    1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
    2. Properly relieve the fuel system pressure.
    3. Drain the coolant system.
    4. Remove or disconnect the following:
      • Negative battery cable
      • Air cleaner fresh air hose
      • Positive Crankcase Ventilation (PCV) valve hose
      • Fuel line from the rail
      • Throttle cable from the throttle body
      • Throttle cable bracket nuts
      • Fuel injector electrical connectors
      • Throttle Position (TP) sensor electrical connectors
      • Idle Air Control (IAC) valve electrical connectors
      • Manifold Absolute Pressure (MAP) sensor electrical connectors
      • Exhaust Gas Recirculation (EGR) valve electrical connectors
      • Heater hose from the intake manifold outlet
    5. Position the wiring harness over the brake master cylinder
    6. Remove or disconnect the following:
      • Intake manifold support bracket bolt
      • Label the vacuum line for proper assembly
      • Drive belt
      • Power steering pump
      • Upper intake manifold bolts
      • Evaporative Emissions (EVAP) canister purge valve solenoid vacuum hose
      • Brake booster vacuum hose
      • Lower intake manifold bolts
      • Intake manifold
      To install:
    7. Thoroughly clean all gasket mating surfaces. Be careful not to damage or score the aluminum surface. If replaced, use Loctite® 290, to seal the new PCV valve inlet tube into the manifold. NOTE: Refer to Section 1 of this manual for the intake manifold torque sequence illustration. The illustration is located after the Torque Specification Chart.
    8. Install or connect the following:
      • New gasket and manifold. Torque the nuts in sequence to 22 ft. lbs. (30 Nm).
      • Power steering pump. Torque the fasteners to 27 ft. lbs. (38 Nm).
      • Drive belt.
      • Heater hose and install the manifold support bracket bolt. Tighten the bolt to 22 ft. lbs. (30 Nm).
      • Lubricate the male ends of the fuel lines with a few drops of clean engine oil, then connect the fuel supply and return lines.
      • Fuel line(s) in the retaining bracket. Torque the mounting screw to 36 inch lbs. (4 Nm).
      • Throttle cable to the throttle body and attach the accelerator cable bracket. Torque the bolts to 22 ft. lbs. (30 Nm).
      • Reposition the wiring harness and connect the wiring and vacuum hoses to their original locations. The harness leads to the TP sensor and EGR solenoid must be routed between the intake manifold runners.
      • Negative battery cable
    9. Fill the coolant system.
    10. Prime the fuel system by cycling the ignition ON for 5 seconds and OFF for 10 seconds a few times without cranking the engine.
    11. Start the engine, check for leaks, and repair if necessary.

    Mar 27, 2009 | 2000 Saturn SL

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