Bonneville, LeSabre, Park Avenue 2000-2005

Intake Manifold

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Removal & Installation



3.8L Engine
VIN 1 Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. 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
     

  8.  

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.  
  3. Refill and bleed the cooling system.
  4.  
  5. Run the engine and check for leaks and proper engine operation.
  6.  

VIN K Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. 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

    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold and related components-3.8L (VIN K) engine

     

  10.  

To install:

Click image to see an enlarged view

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



Click image to see an enlarged view

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.  
  3. Refill and bleed the cooling system.
  4.  
  5. Run the engine and check for leaks and proper engine operation.
  6.  

4.6L Engine
  1. Remove the brake booster hose from the throttle body.
  2.  
  3. Remove the fuel pressure regulator vacuum tube from the fuel pressure regulator and the water crossover.
  4.  
  5. Remove the PCV fresh air feed tube from the camshaft cover and the throttle body.
  6.  
  7. Remove the PCV dirty air tube from the PCV orifice in the right camshaft cover and from the intake manifold.
  8.  
  9. Disconnect the fuel injector electrical connectors from the fuel injectors.
  10.  
  11. Remove the fuel injector wiring harness.
  12.  
  13. Remove the fuel rail bracket nut from the engine lift bracket.
  14.  
  15. Remove the fuel rail studs.
  16.  
  17. Lift and remove the fuel rail with injectors.
  18.  
  19. Loosen the plenum duct clamp in order to remove the intake manifold.
  20.  
  21. Remove the intake manifold bolts.
  22.  
  23. Remove the intake manifold.
  24.  

To install:

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

    Click image to see an enlarged view

    Fig. Intake manifold torque sequence-4.6L engine

  4.  
  5. Tighten the intake manifold bolts in sequence. Tighten the intake manifold bolts to 89 inch lbs. (10 Nm).
  6.  
  7. Tighten the plenum duct clamp to the intake manifold. Tighten the plenum duct clamp to 24 inch lbs. (2.75 Nm).
  8.  
  9. Inspect the fuel injector O-rings. Ensure the fuel injector O-rings are not missing, misaligned or damaged. Replace the O-rings if necessary.
  10.  
  11. Lubricate the intake manifold fuel injector bores with light mineral oil (GM P/N 9981704), clean engine oil, or equivalent.
  12.  
  13. Install the fuel rail with fuel injectors as an assembly.
  14.  
  15. Install the fuel rail studs. Tighten the fuel rail studs to 80 inch lbs. (9 Nm).
  16.  
  17. Install the fuel rail bracket nut to the engine lift bracket. Tighten the fuel rail bracket nut to 89 inch lbs. (10 Nm).
  18.  
  19. Install the fuel injector wiring harness.
  20.  
  21. Connect the fuel injector electrical connectors to the fuel injectors.
  22.  
  23. Install the PCV dirty air tube to the PCV orifice in the right camshaft cover and to the intake manifold.
  24.  
  25. Install the PCV fresh air feed tube to the camshaft cover and the water crossover.
  26.  
  27. Install the fuel pressure regulator vacuum tube to the fuel pressure regulator and the throttle body.
  28.  
  29. Install the brake booster hose to the throttle body.
  30.  

 
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