ParkAvenue 1997-1999

Intake Manifold 1

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Removal & Installation



Specific to:

Buick LeSabre 1986-1999

Buick Park Avenue 1996-1999

Oldsmobile 88 1992-1999

Oldsmobile Delta 88 1986-1988

Oldsmobile LSS 1996-1999

Pontiac Bonneville 1987-1999


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

Specific to:

Buick LeSabre 1998-1999

Buick Park Avenue 1996-1999

Oldsmobile 88 1998-1999

Oldsmobile LSS 1998-1999

Pontiac Bonneville 1998-1999

  1. Properly relieve the fuel system pressure, as outlined in Section 5 of this manual.
  2.  
  3. If not done already, disconnect the negative battery cable.
  4.  
  5. Drain the engine cooling system into a suitable container.
  6.  
  7. Tag and disconnect the right side spark plug wires, then position them aside.
  8.  



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Fig. Disconnect the right side spark plugs, then position the harness aside

  1. Detach the spark plug wires from the fuel injector rail.
  2.  
  3. Unfasten the fuel lines from the fuel rail. Remove the mounting nuts, then remove the fuel rail from the engine.
  4.  
  5. Remove the accelerator control cable bracket bolts, then remove the cable bracket from the manifold.
  6.  



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Fig. Remove the bolts, then remove the accelerator control cable bracket

  1. Unfasten the throttle body nuts, then remove the throttle body. Remove the throttle body gasket.
  2.  



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Fig. Exploded view of the throttle body mounting

The two bolts which hold the lower intake manifold to the cylinder head are only accessible after the upper intake manifold is removed. The bolts are found in the right front and left rear corners of the lower intake manifold. You must remove the upper intake manifold to service the lower manifold.

  1. Unfasten the upper intake manifold bolts and stud, then remove the upper manifold.
  2.  



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Fig. Exploded view of the upper intake manifold mounting

  1. Remove the EGR outlet pipe from the intake manifold.
  2.  
  3. Unfasten the lower intake manifold bolts, then remove the lower manifold and gasket.
  4.  



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Fig. Removing the lower intake manifold and gasket - VIN K engine shown, VIN 1 similar

  1. Thoroughly clean the gasket mating surfaces, bolt and bolt holes.
  2.  

To install:

  1. Position the lower manifold gasket. Install the lower intake manifold.
  2.  
  3. Apply a suitable threadlocking compound to the lower manifold bolts. Install the bolts, including the 2 hidden bolts, and tighten to 11 ft. lbs. (15 Nm), in the sequence shown in the accompanying figures.
  4.  



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Fig. Lower intake manifold bolt tightening sequence - VIN K engine



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Fig. Bolt tightening sequence for the lower intake manifold - VIN 1 engine

  1. Install the EGR outlet pipe to the intake manifold and secure with the mounting bolt. Tighten the bolt to 21 ft. lbs. (29 Nm).
  2.  
  3. Position a new upper intake manifold gasket, then place the upper manifold on the gasket.
  4.  
  5. Install the upper intake manifold bolts, then tighten the bolts to 89 inch lbs. (10 Nm), in the sequence shown in the accompanying figure.
  6.  



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Fig. Upper intake manifold bolt tightening sequence

  1. Install the throttle body gasket and throttle body. Install the retaining nuts and tighten to 89 inch lbs. (10 Nm).
  2.  
  3. Install the engine wiring harness shield bracket and retaining bolt and nut. Tighten to 89 inch lbs. (10 Nm).
  4.  
  5. Install the accelerator control cable bracket. Secure with the bracket retaining bolts and tighten to 12 ft. lbs. (16 Nm).
  6.  
  7. Install the fuel rail and secure with the nuts. Tighten to 89 inch lbs. (10 Nm). Connect the fuel lines.
  8.  
  9. Place the right side spark plug wiring harness in position, then connect the wires as tagged during removal.
  10.  
  11. Fill the cooling system with the proper type and amount of coolant.
  12.  
  13. Connect the negative battery cable, then start the engine and check for leaks. Check the coolant level and add if necessary.
  14.  

Specific to:

Buick Park Avenue 1998-1999

Oldsmobile Regency 1998



Click image to see an enlarged view

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

3.0L And 3.8L (VIN 3 And B) Engines

Specific to:

Buick LeSabre 1986-1990

Buick Park Avenue 1996-1999

Oldsmobile Delta 88 1986-1988

Pontiac Bonneville 1987-1990

  1. Relieve the pressure in the fuel system before disconnecting any fuel line connections. Refer to the procedure in Section 5.
  2.  
  3. If not already done, disconnect the negative battery cable.
  4.  
  5. Remove the mass air flow sensor and air intake duct.
  6.  
  7. Remove the serpentine accessory drive belt, alternator and bracket.
  8.  
  9. Remove the ignition coil module, TV cable, throttle cable and cruise control cable.
  10.  
  11. Tag and disconnect all necessary vacuum hoses and electrical wiring.
  12.  
  13. Drain the cooling system into a suitable container. Disconnect the heater hoses from the throttle body and upper radiator hose.
  14.  
  15. Disconnect the fuel lines from the fuel rail and injectors.
  16.  
  17. Unfasten the intake manifold retaining bolts and remove the intake manifold and gasket.
  18.  



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Fig. You must tighten the intake manifold bolts in the proper sequence - 3.0L and 3.8L (VIN 3 and B) engine

To install:

  1. Clean the cylinder head and intake manifold surfaces from any foreign matter, nicks or heavy scratches.
  2.  
  3. Install the intake manifold gasket and rubber seals. Apply sealer 1050026 or equivalent, on the gasket. Apply sealer/lubricant 1052080 or equivalent, to all pipe thread fittings.
  4.  
  5. Carefully position the intake manifold on the cylinder block. Install the intake manifold bolts, then tighten them in sequence to 47 ft. lbs. (65 Nm).
  6.  
  7. Connect the fuel lines to the fuel rail and injectors.
  8.  
  9. Install the heater hoses to the throttle body and upper radiator hose.
  10.  
  11. Connect all vacuum hoses and electrical wiring, as tagged during removal.
  12.  
  13. Install the ignition coil module, TV cable, throttle cable and cruise control cable.
  14.  
  15. Install the bracket, alternator and serpentine belt.
  16.  
  17. Install the mass air flow sensor and air intake duct.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Fill cooling system and check for leaks. Start the engine and allow to come to normal operating temperature. Recheck for leaks. Check coolant level and add if necessary.
  22.  

3.8L Engine
VIN 1 Engine

Specific to:

Buick LeSabre 1996-1997

Buick Park Avenue 1996-1999

Oldsmobile 88 1996-1997

Oldsmobile LSS 1996-1997

Pontiac Bonneville 1996-1997

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the front splash shield.
  6.  
  7. Drain the engine coolant into a suitable container. Don't forget to close the radiator draincock.
  8.  
  9. Install the front splash shield.
  10.  
  11. Carefully lower the vehicle.
  12.  
  13. Remove the supercharger, as outlined in this section.
  14.  
  15. Remove the thermostat housing.
  16.  
  17. Disconnect the EGR tube from the intake manifold.
  18.  
  19. Detach the electrical connection from the temperature sensor.
  20.  
  21. Unfasten the retainers, then remove the intake manifold from the vehicle. If equipped, remove and discard the intake manifold gasket. Thoroughly clean the gasket mating surfaces, bolts and bolt holes.
  22.  

To install:

  1. Position a new gasket or seal(s), as applicable, then install the intake manifold. Install a suitable threadlocking compound to the intake manifold bolts. Install the bolts and tighten to 11 ft. lbs. (15 Nm), in the sequence shown in the accompanying figure.
  2.  
  3. Attach the electrical connector to the temperature sensor.
  4.  
  5. Connect the EGR tube to the intake manifold.
  6.  
  7. Install the thermostat housing.
  8.  
  9. Install the supercharger, as outlined in this section.
  10.  
  11. Fill the cooling system with the proper type and amount of coolant.
  12.  
  13. Connect the negative battery cable, then start the engine and check for leaks. Check the coolant level and add if necessary.
  14.  

Specific to:

Buick Park Avenue 1998-1999

Oldsmobile Regency 1998

  1. Before servicing the vehicle, refer to the precautions in the beginning of this 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 C Engine

Specific to:

Buick LeSabre 1986-1990

Buick Park Avenue 1996-1999

Oldsmobile Delta 88 1986-1988

Pontiac Bonneville 1987-1990

  1. Properly relieve the fuel system pressure, as outlined in Section 5.
  2.  
  3. If not already done, disconnect the negative battery cable.
  4.  
  5. Disconnect the fuel lines from the fuel rail.
  6.  
  7. Place a clean drain pan under the radiator, open the draincock and drain the cooling system.
  8.  
  9. Remove the serpentine drive belt, alternator and bracket.
  10.  



Click image to see an enlarged view

Fig. Unfasten the 3 mounting bolts, then remove the alternator bracket (with the ignition coil attached)

  1. Disconnect the coolant bypass hose, the heater pipe and the upper radiator hose from the intake manifold.
  2.  



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Fig. Disconnect the coolant bypass hose from the intake manifold



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Fig. Detach the heater pipe from the intake manifold

  1. Remove the power steering pump and braces, and move them aside; do not disconnect the pressure lines.
  2.  



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Fig. Unfasten the power steering pump brace retaining bolts



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Fig. Remove the power steering pump brace

  1. Remove the vacuum hoses and tag and detach the electrical connectors from the intake manifold.
  2.  
  3. Remove the EGR pipe, EGR valve and adapter from the throttle body.
  4.  



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Fig. The EGR pipe is located on the side of the front valve cover (see arrow)



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Fig. Unfasten the hose clamp, then disconnect the EGR pipe

  1. Remove the throttle body coolant pipe, the throttle body and the throttle body adapter.
  2.  



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Fig. Unfasten the throttle body adapter retaining bolts ...



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Fig. ... then remove the throttle body adapter



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Fig. Remove the throttle body adapter gasket

  1. Disconnect the rear spark plug wires. Unfasten the intake manifold-to-engine bolts and remove the manifold.
  2.  



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Fig. Overview of the intake manifold and retaining bolt tightening sequence



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Fig. Remove the intake manifold retaining bolts ...



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Fig. ... then lift the manifold up and remove it from the vehicle

  1. Remove and discard the manifold gaskets and seals, then clean the gasket mating surfaces.
  2.  



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Fig. Remove the intake manifold gaskets ...



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Fig. ... and the seals from each end of the manifold



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Fig. A piece of Scotchbrite®, or similar non-abrasive scouring pad, works well to clean the manifold gasket mating surfaces

To install:

  1. Install new gaskets and the proper sealant on the ends of the manifold seals.
  2.  
  3. Install the intake manifold and tighten the mounting bolts, in sequence, twice to 88 inch lbs. (10 Nm).
  4.  
  5. Connect the rear spark plug wires.
  6.  
  7. Install the throttle body adapter, throttle body and throttle body coolant pipe. Tighten the bolts to 20 ft. lbs. (27 Nm).
  8.  
  9. Install the EGR valve and adapter. Replace the EGR pipe.
  10.  
  11. Connect the vacuum hoses and the electrical connections to the intake manifold.
  12.  
  13. Install the coolant pipe, upper radiator hose and the upper bypass hose to the intake manifold.
  14.  
  15. Install the power steering pump and bracket assembly.
  16.  
  17. Install the alternator and bracket assembly. Replace the serpentine belt.
  18.  
  19. Refill the cooling system and connect the negative battery cable. Start the engine, allow it to reach normal operating temperatures and check for leaks.
  20.  

VIN K Engine

Specific to:

Buick Park Avenue 1998-1999

Oldsmobile Regency 1998

  1. Before servicing the vehicle, refer to the precautions in the beginning of this 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
     
    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
     
    Upper radiator hose
     
    Serpentine belt
     
    Alternator
     
    Drive belt tensioner assembly
     
    EGR valve outlet pipe
     
    Lower intake manifold
     

  10.  

To install:

Click image to see an enlarged view

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



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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).
     
    Alternator
     
    Drive belt
     
    Upper radiator hose to the thermostat housing
     
    Upper intake plenum. Torque the intake plenum bolts to 11 ft. lbs. (15 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
     
    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.  

 
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