The proper way to install intake manifold - 1996 Mercury Grand Marquis

Not easy but doable. I would mark anything you aren't familiar with to get it back together right. Please let me know if you have any questions, and thanks for using FixYa.


IGNITION COIL REMOVAL & INSTALLATION
3.0L Engine

1. Remove the wiper arms
2. Remove the left and right side air inlet grilles
3. Remove the wiper motor.
4. Detach the power brake booster vacuum connection from the intake plenum.
5. Disconnect the spark plug wiring harness from the ignition coil.
6. Detach the electrical connection from the ignition coil.
7. Remove the bolts from the ignition coil, and remove the coil.

To install:

1. Installation is the reversal of the removal procedure.
2. Tighten the coil bolts to 71 inch lbs. 8 (Nm).
3. Tighten the power brake booster vacuum connection until snug.

valve cover removal & installation3.0L Engine
RIGHT

1. Disconnect the negative battery cable.
2. Remove the intake plenum and the intake manifold.
3. Remove the spark plug boots from the spark plugs, and then the wires from the routing retainers. Make sure they are tagged for proper installation.
4. Remove the rocker arm cover-to-cylinder screws, the cover, and the gasket/seals. Discard the seals.

NOTE Ensure all eight sealing O-rings are accounted for. They may stick to the camshaft bearing caps or fall into the oil return journals in the cylinder head.

Fig. The location of the valve cover O-rings is shown here

Fig. The valve cover sealant application points
To install:

1. Install new valve cover seals. Lightly coat the new seals, including O-rings, with engine oil prior to installation. The oil application will assist in holding the O-ring seals to the valve cover.
2. Apply a thin coat of silicone sealer at the front and back of the seals.
3. Install the valve cover to the cylinder head, and tighten the bolts to 71 inch lbs. (8 Nm).
4. Route the spark plug wires into the retainers, and install the plug boots to the spark plugs.
5. Replace the intake manifold and the intake plenum.
6. Connect the negative battery cable.

LEFT

1. Disconnect the negative battery cable.
2. Remove the intake plenum and the intake manifold.
3. Remove the spark plug boots from the spark plugs, and then the wires from the routing retainers. Make sure they are tagged for proper installation.
4. Remove the oil filler spout.
   1. Unlock the tab.
   2. Twist counterclockwise.
   
   
5. Remove the rocker arm cover-to-cylinder screws, the cover, and the gasket/seals. Discard the seals.

NOTE Ensure all eight sealing O-rings are accounted for. They may stick to the camshaft bearing caps or fall into the oil return journals in the cylinder head.
To install:

1. Install new valve cover seals. Lightly coat the new seals, including O-rings, with engine oil prior to installation. The oil application will assist in holding the O-ring seals to the valve cover.
2. Apply a thin coat of silicone sealer at the front and back of the seals.
3. Install the valve cover to the cylinder head, and tighten the bolts to 71 inch lbs. (8 Nm).
4. Install the oil filler spout.
   1. Insert the spout and twist clockwise.
   2. Ensure the locking tab seats on the valve cover bolt head.
   
   
5. Route the spark plug wires into the retainers, and install the plug boots to the spark plugs.
6. Replace the intake manifold and the intake plenum.
7. Connect the negative battery cable.

INTAKE MANIFOLD REMOVAL & INSTALLATION

3.0L Engine
This vehicle uses a sequential multiport fuel injected engine. Fuel injector connectors must be positioned onto their appropriate fuel injector or engine performance and exhaust emissions may be seriously affected. Fuel injector connectors are numbered to match their cylinders.

1. Remove the intake plenum.
2. Properly relieve the fuel system pressure.
3. Remove the fuel supply and fuel return hose from the fuel rail.
4. Fuel injector electrical harness connector.
5. Remove the intake manifold bolts and the intake manifold.

NOTE Mask off the ports to the intake manifold spacer. If foreign objects enter the engine, severe damage may result.
Clean the intake manifold sealing surfaces with a non-abrasive tool or solvent.
Do not damage machined aluminum surfaces or improper sealing may occur.

Fig. Location of the guide pins for the intake plenum-3.0L engine

Fig. Intake plenum-to-intake manifold mounting

Fig. The intake manifold bolt locations
To install:

1. Remove the masking from the intake ports.
2. Install the intake manifold, and tighten the intake bolts to 15 ft. lbs. (20 Nm), rotating the tightening sequence.
3. Reconnect the fuel injector electrical harness connector.
4. Couple the fuel supply and fuel return hose,. Tighten the connection to 11 ft. lbs. (15 Nm).

NOTE Counterhold the connections to prevent damage to the fuel rail.

1. Install the intake plenum.
2. Connect the negative battery cable.

Exactly what is the wrong? Need the part? Need to know torque adjust or porcedure to take off?

For 1994 Pontiac Grand Am 3.1L SFI OHV 6cyl check this procedure for Intake Manifold...
(see Figure 14)
The 3.1L engine is equipped with upper and lower intake manifolds. The upper intake manifold is also known as the intake manifold plenum.

CAUTION The fuel system is under pressure and must be properly relieved before disconnecting the fuel lines. Failure to properly relieve the fuel system pressure can lead to personal injury and component damage.

1. Relieve the fuel system pressure.
2. Disconnect the negative battery cable.
3. Remove top half of the air cleaner assembly and throttle body duct.
4. Drain and recycle the engine coolant.
5. Disconnect the EGR pipe from exhaust manifold.
6. Remove the serpentine belt.
7. Remove the brake vacuum pipe at the intake plenum.
8. Disconnect the control cables from the throttle body and intake plenum mounting bracket.
9. Remove the power steering lines at the alternator bracket.
10. Remove the alternator.
11. Label and disconnect the ignition wires from the spark plugs and wire retainers on the intake plenum.
    
12. Remove the ignition assembly and the EVAP canister purge solenoid together.

Fig. 14: View of the intake manifold and related components

1. Disconnect the upper engine wiring harness connectors at the following components:
   Throttle Position Sensor (TPS) Idle Air Control (IAC) Fuel Injectors Coolant temperature sensor Manifold Absolute Pressure (MAP) sensor Camshaft Position (CMP) sensor
2. Tag and disconnect the vacuum lines from the following components:
   Vacuum modulator Fuel pressure regulator PCV valve
3. Disconnect the MAP sensor from upper intake manifold.
4. Remove the upper intake plenum mounting bolts and lift off the plenum.
5. Disconnect the fuel lines from the fuel rail and bracket.
6. Install engine support fixture special tool J 28467-A or an equivalent.
7. Remove the right side engine mount.
8. Remove the power steering mounting bolts and support the pump out of the way without disconnecting the power steering lines.
9. Disconnect the coolant inlet pipe from the outlet housing.
10. Remove the coolant bypass hose from the water pump and the cylinder head.
11. Disconnect the upper radiator hose at thermostat housing.
12. Remove the thermostat housing.
13. Remove both rocker arm covers.
14. Remove the lower intake manifold bolts. Make sure the washers on the four center bolts are installed in their original locations.
    

When removing the valve train components they should be kept in order for installation the original locations.

1. Remove the rocker arm retaining nuts or bolts and extract the rocker arms and pushrods.
2. Remove the intake manifold from the engine. Remove and discard the gasket.
3. Using a suitable scraper, clean gasket material from all mating surfaces. Remove all excess RTV sealant from front and rear ridges of cylinder block
   

To install:

1. Place a 0.12 inch (3mm) bead of RTV, on each ridge, where the front and rear of the intake manifold contact the block.
2. Using a new gasket, place the intake manifold on the engine.
3. Install the pushrods in their original locations. Coat the pushrods with prelube.

The intake pushrods are marked yellow (5 3 /4 inch long) and the exhaust are green (6 inches long). Make sure the pushrods are properly seated in the valve lifters and rocker arms.

1. Position the rocker arms in there original locations and tighten to specifications. Refer to the procedure earlier in this section.
2. Install lower the intake manifold attaching bolts. Apply sealant 12345739 (or equivalent thread locking compound) to the threads of bolts. Tighten the vertical bolts first then the diagonal bolts to 115 inch lbs. (13 Nm).
3. Install the front rocker arm cover.
4. Install the thermostat housing.
5. Connect the upper radiator hose to the thermostat housing.
6. Fasten the coolant inlet pipe to thermostat housing.
7. Connect coolant bypass pipe at the water pump and cylinder head.
8. Install the power steering pump in the mounting bracket.
9. Loosely install the serpentine belt.
10. Connect the right side engine mount.
11. Remove the special engine support tool.
12. Fasten the fuel lines to fuel rail and bracket.
13. Install the upper intake manifold and tighten the mounting bolts to 18 ft. lbs. (25 Nm).
14. Install the MAP sensor.
15. Connect the upper engine wiring harness connectors to the related components removed earlier.
16. Connect the vacuum lines to the PCV, vacuum modulator and fuel pressure regulator.
17. Install the EVAP canister purge solenoid and ignition assembly.
18. Install the alternator assembly.
19. Connect the power steering line to the alternator bracket.
20. Install the serpentine belt.
21. Connect the spark plug wires to the spark plugs and intake plenum wire retainer.
22. Install the EGR pipe to the exhaust manifold.
23. Attach the control cables to the throttle body lever and upper intake plenum mounting bracket.
24. Install air intake assembly and top half of the air cleaner assembly.
25. Install the brake vacuum pipe.
26. Fill the cooling system.
27. Connect the negative battery cable, then start the vehicle and verify that there are no leaks.

For PARTS REPLACEMENT check in THIS LINK: carpartswholesale.com

Hope helps.

Hello,

Here is a detailed summary on the procedure of how to replace the intake manifold gasket on a 1996 gmc jimmy;
REMOVING THE UPPER INTAKE MANIFOLD(PLENUM)
STEP 1 Disconnect Battery (may not be absolutely necessary, but a good practice to avoid shorting a positive wire to ground).


STEP 2 Remove serpentine belt.

STEP 3 Drain the coolant.

STEP 4 Remove air cleaner ducting and disconnect wires.

STEP 5 Disconnect throttle linkage and bracket.

STEP 6 Disconnect cruise control cable.

STEP 7 Remove brake booster vacuum hose at manifold.

STEP 8 Remove PCV hose.

STEP 9 Remove ignition coil and bracket.

STEP 1O Remove purge solenoid and bracket.

STEP 11 Relieve fuel pressure at test port.

STEP 12 Remove fuel lines and bracket.

STEP 13 Remove upper intake manifold.

REMOVING THE LOWER INTAKE MANIFOLD
STEP 1 Remove the distributor and label the spark plug wires.

STEP 2 Remove heater hoses and bypass hose.

STEP 3 Remove upper radiator hose.


STEP 4 Remove EGR valve?

STEP 5 Remove sensors and bracket on right side.

STEP 6 Remove EGR tube, clamp and bolt.

STEP 7 Remove PCV valve (and replace).

STEP 8 Unbolt A/C compressor and move it aside.

STEP 9 Loosen compressor bracket and slide forward, but do not remove it.

STEP 10 Remove alternator bracket bolt (or remove alternator and set aside)

STEP 11 Unplug all vacuum lines from intake manifold.


STEP 12 Unplug all electrical connectors from manifold.

STEP 13 Take note of the intake manifold bolts and mark the location of the bolts.


STEP 14 Remove intake manifold bolts, and manifold.

STEP 15 Clean mating surfaces

THE MAIN INSTALLATION
STEP1 Set the new gaskets in place and apply silicone to flat areas on front and rear of engine block.

STEP2 Apply thread locking compound to manifold bolts.

STEP 3 Install the manifold and tighten bolts to 35 ft-lbs, in proper sequence.

STEP4 Install the distributor.

STEP5 Install the upper intake manifold.



The remaining installation procedures are basically the reverse of removal.


Have a nice day.

You didn't post the size of your engine so please pick the appropriate one:

3.8L

1. Relieve the fuel system pressure.
   
2. Drain the cooling system.
   

1. Remove or disconnect the following:
2. Negative battery cable
   

• Supercharger
  
• Thermostat housing
  
• Exhaust Gas Recirculation (EGR) tube at the intake manifold
  
• Engine Control Temperature (ECT) sensor
  
• Intake manifold
  

To install:

1. Install or connect the following:
   
   • Intake manifold with new gaskets. Torque the bolts, working from the center out, to 11 ft. lbs. (15 Nm).
     
   • ECT sensor connector
     
   • EGR tube to the intake manifold
     
   • Thermostat housing
     
   • Supercharger
     
   • Negative battery cable
     
2. Refill and bleed the cooling system.
   
3. Run the engine and check for leaks and proper engine operation.
   

4.6L
4.6L Engine

1. Remove the brake booster hose from the throttle body.
   
2. Remove the fuel pressure regulator vacuum tube from the fuel pressure regulator and the water crossover.
   
3. Remove the PCV fresh air feed tube from the camshaft cover and the throttle body.
   
4. Remove the PCV dirty air tube from the PCV orifice in the right camshaft cover and from the intake manifold.
   
5. Disconnect the fuel injector electrical connectors from the fuel injectors.
   
6. Remove the fuel injector wiring harness.
   
7. Remove the fuel rail bracket nut from the engine lift bracket.
   
8. Remove the fuel rail studs.
   
9. Lift and remove the fuel rail with injectors.
   
10. Loosen the plenum duct clamp in order to remove the intake manifold.
    
11. Remove the intake manifold bolts.
    
12. Remove the intake manifold.
    

To install:

1. Install the intake manifold, fitting the plenum duct over the intake manifold duct.
   
2. Loosely install the intake manifold bolts.
   

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Intake manifold torque sequence-4.6L engine

2. Tighten the intake manifold bolts in sequence. Tighten the intake manifold bolts to 89 inch lbs. (10 Nm).
   
4. Tighten the plenum duct clamp to the intake manifold. Tighten the plenum duct clamp to 24 inch lbs. (2.75 Nm).
   
5. Inspect the fuel injector O-rings. Ensure the fuel injector O-rings are not missing, misaligned or damaged. Replace the O-rings if necessary.
   
6. Lubricate the intake manifold fuel injector bores with light mineral oil (GM P/N 9981704), clean engine oil, or equivalent.
   
7. Install the fuel rail with fuel injectors as an assembly.
   
8. Install the fuel rail studs. Tighten the fuel rail studs to 80 inch lbs. (9 Nm).
   
9. Install the fuel rail bracket nut to the engine lift bracket. Tighten the fuel rail bracket nut to 89 inch lbs. (10 Nm).
   
10. Install the fuel injector wiring harness.
    
11. Connect the fuel injector electrical connectors to the fuel injectors.
    
12. Install the PCV dirty air tube to the PCV orifice in the right camshaft cover and to the intake manifold.
    
13. Install the PCV fresh air feed tube to the camshaft cover and the water crossover.
    
14. Install the fuel pressure regulator vacuum tube to the fuel pressure regulator and the throttle body.
    
15. Install the brake booster hose to the throttle body.
    

Here is the removal procedure, and the procedure is the same for both the V-6 and the V-8 Vortec engines. Also, be certain to put engine oil on the "o"-ring seal for the fuel injector assembly before installing the upper intake. Let me know if you require any further assistance.

REMOVAL:

1. Disconnect the battery negative cable assembly from the battery negative terminal.

2. Remove the air cleaner assembly.

3. Remove the wiring harness connectors and the brackets and move aside.

4. Remove the throttle cable and the bracket from the upper intake manifold.

5. Remove the cruise control cable, (if equipped).

6. Remove the fuel lines from the intake to the rear of the block.

7. Remove the ignition coil and the bracket.

8. Remove the upper intake manifold.

INSTALLATION:

1. Install the upper intake manifold gasket.

2. Install the upper intake manifold. Use care not to pinch the injector lines between the upper and lower intake manifolds.

3. Install the upper intake manifold bolts. Note the marks made at disassembly for proper stud location. Install the two corner studs first in order to help align the two halves. NOTE: Other than the two torque passes listed below, the OE Manufacturer did NOT address or supply a bolt tightening sequence for the upper Intake Manifold for this model year, or other model years where this 2 piece manifold setup is used. A "Play It Safe" final tightening sequence would be to tighten from the center most bolts to the outer most bolts.

4. Tighten the bolts in two steps: a. Tighten the bolts on the first sequence to 5 Nm (44 inch lbs.). b. Tighten the bolts on the final sequence to 10 Nm (88 inch lbs.).

5. Install the purge solenoid and bracket.

6. Install the ignition coil and bracket.

7. Install the PCV hose et the upper intake manifold.

8. Install the fuel lines from the intake at the rear of the block.

9. Install the cruise control cable (if equipped).

10. Install the throttle cable and bracket from the upper intake manifold.

11. Install the wiring harness connectors and brackets.

12. Install the air cleaner assembly.

13. Connect the battery negative cable assembly to the battery negative terminal. - Tighten the bolt to 15 Nm (11 ft. lbs.).

Fig. Exploded view of the upper and lower intake manifold and fasteners

- Position the rocker arms in their original locations and tighten to the proper specifications.
- Install lower the intake manifold attaching bolts. Apply sealant or equivalent thread locking compound to the threads of bolts. Tighten the vertical bolts first, then the diagonal bolts to 115 inch lbs. (13 Nm).
- Install the upper intake manifold and tighten the mounting bolts to 18 ft. lbs. (25 Nm).

Hope helps (remember to rate this).

Bonneville, LeSabre, Park Avenue 2000-2005 Intake Manifold - Removal & Installation

3.8L Engine
VIN 1 Engine

1. Before servicing the vehicle, refer to the Precautions section.
2. Relieve the fuel system pressure.
3. Drain the cooling system.
4. Remove or disconnect the following:
   Negative battery cable Supercharger Thermostat housing Exhaust Gas Recirculation (EGR) tube at the intake manifold Engine Control Temperature (ECT) sensor Intake manifold

To install:

1. Install or connect the following:
   Intake manifold with new gaskets. Torque the bolts, working from the center out, to 11 ft. lbs. (15 Nm). ECT sensor connector EGR tube to the intake manifold Thermostat housing Supercharger Negative battery cable
2. Refill and bleed the cooling system.
3. Run the engine and check for leaks and proper engine operation.

VIN K Engine

1. Before servicing the vehicle, refer to the Precautions section.
2. Disconnect the negative battery cable.
3. Drain the cooling system.
4. Relieve the fuel system pressure.
5. Remove or disconnect the following:
   Fuel injector sight shield Air inlet duct Spark plug wires from the right side Manifold Absolute Pressure (MAP) sensor Vacuum lines from the intake manifold Fuel lines Fuel injector electrical connectors Fuel regulator vacuum line Fuel rail from the intake manifold Exhaust Gas Recirculation (EGR) heat shield Throttle cable bracket from the cylinder head mounting bracket and the throttle body cables Throttle body support bracket Upper intake plenum and gasket Thermostat housing Electrical connector from the Engine Coolant Temperature (ECT) sensor Drive belt tensioner assembly EGR valve outlet pipe Lower intake manifold
   
   
   Fig. Exploded view of the intake manifold and related components-3.8L (VIN K) engine
   

To install:



Fig. Upper intake manifold torque sequence-3.8L (VIN K) engine



Fig. Lower intake manifold torque sequence-3.8L (VIN K) engine

1. Install or connect the following:
   Intake manifold using new manifold gaskets. Torque the bolts in sequence to 11 ft. lbs. (15 Nm); then, re-torque to 11 ft. lbs. (15 Nm). EGR valve outlet pipe Drive belt tensioner assembly. Torque the tensioner bolts to 37 ft. lbs. (50 Nm). Electrical connector to the ECT sensor Thermostat housing Upper intake plenum. Torque the intake plenum bolts to 88 inch. lbs. (10 Nm). Throttle body support bracket Throttle cable bracket to the cylinder head mounting bracket and the cables to the throttle body lever EGR heat shield Fuel rail. Torque the fuel rail bolts to 88 inch. lbs. (10 Nm). Fuel lines Fuel regulator vacuum line Fuel injector electrical connectors Vacuum lines to the intake manifold MAP sensor Spark plug wires Fuel injector sight shield and air inlet duct Negative battery cable
2. Refill and bleed the cooling system.
3. Run the engine and check for leaks and proper engine operation.

Hope this help (remember rated this).

Position The Intake Manifold Gasket On The Engine.Dowels May Be Provided To Hold The Gasket In Place During Manifold Installation.. The Use Of Silicone Sealer Is Required. Especially Where The Front And The Rear Seals Meet The Side Gaskets On V-type Engines. Installing An Intake Manifold On V-type Engines Can Be Difficult. It Is Critical That You Use Sealer Properly On The Engine To Prevent Vacuum,Coolant, And Oil Leaks.

Start All The Fasteners By Hand Before Tightening. This Will Aid In Bolt Hold Alignment. Then Torque The Intake Manifold Fasteners To Specifications. Use The Specific Torque Pattern Given In The Service Manual.. Basically The Pattern Will Be A Crisscross Pattern

This is the entire task for it. It sounds like you might not have torqued it correctly, or your intake is cracked. But take a look at all of the info:

VIN K Engine On these engines, the upper and lower intake manifolds must be removed separately.

1. Properly relieve the fuel system pressure, as outlined in Section 5 of this manual.
   
2. Disconnect the negative battery cable.
   
3. Drain the cooling system into a suitable container.
   
4. Remove the fuel injector sight shield and air intake duct.
   
5. Tag and disconnect the spark plug wires on the right side of the engine and position aside.
   
6. Remove the manifold vacuum source.
   
7. Remove the fuel rail.
   
8. Remove the EGR heat shield.
   
9. Unfasten the cable bracket-to-cylinder head mounting bolt.
   
10. Disconnect the throttle cable.
    
11. Remove the throttle body support bracket.
    
12. Unfasten the upper intake manifold bolts, then remove the upper manifold.
    

This engine has two bolts which are hidden beneath the upper intake. These bolts are located in the right front and left rear corners of the lower intake manifold. This is why it is necessary to remove the upper before servicing the lower manifold.

1. Disconnect the upper radiator hose.
   
2. Remove the alternator, as outlined in Section 2 of this manual.
   
3. Remove the drive belt tensioner.
   
4. Remove the EGR valve outlet pipe.
   
5. Unfasten the intake manifold bolt, then remove the manifold from the vehicle. Remove and discard the gaskets. Thoroughly clean the gasket mating surfaces, intake manifold bolts and bolt holes.
   

To install:

1. Position a new gasket, then place the lower intake manifold over it. Apply a suitable threadlocking compound to the bolts, then install them. For 1995 vehicles, tighten the bolts twice, to 88 inch lbs. (10 Nm), in the sequence shown in the accompanying figure. For 1996-97 vehicles, tighten the bolts to 11 ft. lbs. (15 Nm), in the sequence shown in the accompanying figure.
   
1. Install the EGR valve outlet pipe.
   
2. Install the drive belt tensioner.
   
3. Install the alternator.
   
4. Connect the upper radiator hose.
   
5. Position the upper intake manifold on the lower manifold. Install the retaining bolts and tighten to 89 inch lbs. (10 Nm).
   
6. Install the throttle body support bracket, then connect the throttle cable.
   
7. Install the cable bracket-to-cylinder head mounting bolt.
   
8. Install the EGR heat shield.
   
9. Install the fuel rail.
   
10. Install the manifold vacuum source.
    
11. Connect the right side spark wires on the right side of the engine.
    
12. Install the fuel injector sight shield and air intake duct.
    
13. Fill the cooling system with the proper type and amount of fluid.
    
14. Connect the negative battery cable. Start the engine and check for leaks. Check the cooling system, and add as necessary.
    

1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
2. Drain the engine oil.
3. Remove or disconnect the following:
   
   Negative battery cable Intake manifold bracket upper bolts Clutch release cylinder and move it aside, if equipped Intake manifold bracket lower bolts and remove the bracket Starter from the clutch, manual transmissions only Starter from the torque converter, automatic transmissions only Starter electrical connectors Move the transmission wire harness aside Starter
   
   
   Fig. Exploded view of the starter
   

To install:

1. Install or connect the following:
   
   Starter to the engine well Starter electrical connectors Lower intake manifold bracket and install the upper bolts Starter into position. When aligned properly torque the bolts to 40 ft. lbs. (54 Nm). Torque the intake manifold bracket bolts to 40 ft. lbs. (54 Nm). Properly position the clutch release cylinder, if equipped. Torque the bolts to 40 ft. lbs. (54 Nm). Torque the intake manifold bracket upper bolts to 40 ft. lbs. (54 Nm). Negative battery cable