ParkAvenue 1997-1999

Intake Manifold 2

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Removal & Installation



Except 1995-97 VIN 1 And K Engines

Specific to:

Buick LeSabre 1991-1997

Buick Park Avenue 1996-1999

Oldsmobile 88 1992-1997

Oldsmobile LSS 1996-1997

Pontiac Bonneville 1991-1997

  1. Remove the plastic engine cover and air intake duct.
  2.  
  3. Properly relieve the fuel system pressure, as outlined in Section 5 of this manual. If not already done, disconnect the negative battery cable.
  4.  
  5. Tag and disconnect the spark plug wires on the right side of the engine and set aside.
  6.  
  7. Remove the fuel rail from the vehicle.
  8.  
  9. Remove the exhaust crossover heat shield.
  10.  
  11. Unfasten the cable bracket-to-cylinder head mounting bolt.
  12.  
  13. Remove the power steering pump bracket.
  14.  
  15. Loosen the alternator mounting bolts, then position the alternator aside for clearance.
  16.  
  17. Remove the alternator bracket.
  18.  
  19. Disconnect the heater pipes and bypass hose.
  20.  
  21. Unfasten the retaining bolts, then remove the intake manifold from the vehicle. Remove and discard the gasket and thoroughly clean the gasket mating surfaces and intake manifold bolts and bolt holes.
  22.  



Click image to see an enlarged view

Fig. Exploded view of the intake manifold and gaskets - 1991 3.8L (VIN C) engine shown, later models similar



Click image to see an enlarged view

Fig. Intake manifold bolt tightening sequence - 1991-95 vehicles

To install:

  1. Apply a suitable sealer to the ends of the manifold seals.
  2.  
  3. Position a new intake manifold gasket, then place the intake manifold over it. Apply a suitable threadlocking sealer to the retaining bolts, then install and tighten them twice, in the sequence shown in the accompanying figure, to 88 inch lbs. (10 Nm).
  4.  
  5. Connect the bypass hose and the heater pipes.
  6.  
  7. Install the alternator bracket. Move the alternator into position, then tighten the mounting bolts.
  8.  
  9. Install the power steering pump bracket.
  10.  
  11. Tighten the cable bracket-to-cylinder head mounting bolt.
  12.  
  13. Install the exhaust crossover heat shield.
  14.  
  15. Install the fuel rail in the vehicle.
  16.  
  17. Connect the right side spark plug wires, as tagged during removal.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Install the air intake duct and engine cover.
  22.  

VIN 1 Engine

Specific to:

Buick LeSabre 1995

Buick Park Avenue 1996-1999

Oldsmobile 88 1995

Pontiac Bonneville 1995

  1. Properly relieve the fuel system pressure, as outlined in Section 5 of this manual.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system into a suitable container.
  6.  
  7. Remove the fuel injector sight shield and air intake duct.
  8.  
  9. Tag and disconnect the spark plug wires from the right side of the engine and position it aside.
  10.  
  11. Remove the manifold vacuum source.
  12.  
  13. Disconnect the fuel feed and return lines.
  14.  
  15. Disconnect the upper radiator hose and bypass hose.
  16.  
  17. Tag and detach the electrical connectors from the following components:
    1. EGR valve.
    2.  
    3. Throttle Position (TP) sensor.
    4.  
    5. Idle Air Control (IAC) solenoid.
    6.  
    7. Fuel injectors.
    8.  
    9. Manifold Air Pressure (MAP) solenoid.
    10.  

  18.  
  19. Disconnect the EGR outlet pipe.
  20.  
  21. Detach the throttle and cruise cables.
  22.  
  23. Unbolt the throttle bracket with the power steering reservoir and position aside.
  24.  
  25. Remove the inner accessory drive belt.
  26.  
  27. Disconnect the heater hose pipe from the intake manifold.
  28.  
  29. Remove the tensioner bracket-to-supercharger retaining stud using the standard double nut procedure.
  30.  
  31. Unfasten the intake manifold bolts, 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.
  32.  

To install:

  1. Apply a suitable sealer to the ends of the manifold seals.
  2.  
  3. Position a new intake manifold gasket. Apply a suitable threadlocking compound to the threads of the intake manifold bolts.
  4.  
  5. Install the intake manifold, then secure with the mounting bolts. Tighten the bolts to 11 ft. lbs. (15 Nm).
  6.  
  7. Install the tensioner bracket.
  8.  
  9. Connect the heater hose pipe to the intake.
  10.  
  11. Install the inner accessory drive belt.
  12.  
  13. Place the throttle bracket, with the power steering reservoir, in position and secure with the retainers.
  14.  
  15. Connect the throttle and cruise cables.
  16.  
  17. Attach the EGR outlet pipe.
  18.  
  19. Attach the electrical connectors to the following components, as tagged during removal:
    1. MAP sensor.
    2.  
    3. Fuel injectors.
    4.  
    5. Idle Air Control (IAC) solenoid.
    6.  
    7. TP sensor.
    8.  
    9. EGR valve.
    10.  

  20.  
  21. Connect the upper radiator hose and bypass hose.
  22.  
  23. Attach the fuel feed and return lines.
  24.  
  25. Fill the cooling system with the proper type and amount of coolant.
  26.  
  27. Install the manifold vacuum source.
  28.  
  29. Connect the spark plug wires on the right side of the engine, as tagged during removal.
  30.  
  31. Install the fuel injector sight shield and air intake duct.
  32.  
  33. Connect the negative battery cable.
  34.  

VIN K Engine

Specific to:

Buick LeSabre 1995-1997

Buick Park Avenue 1996-1999

Oldsmobile 88 1995-1997

Oldsmobile LSS 1996-1997

Pontiac Bonneville 1995-1997

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.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system into a suitable container.
  6.  
  7. Remove the fuel injector sight shield and air intake duct.
  8.  
  9. Tag and disconnect the spark plug wires on the right side of the engine and position aside.
  10.  
  11. Remove the manifold vacuum source.
  12.  
  13. Remove the fuel rail.
  14.  
  15. Remove the EGR heat shield.
  16.  
  17. Unfasten the cable bracket-to-cylinder head mounting bolt.
  18.  
  19. Disconnect the throttle cable.
  20.  
  21. Remove the throttle body support bracket.
  22.  
  23. Unfasten the upper intake manifold bolts, then remove the upper manifold.
  24.  

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.  
  3. Remove the alternator, as outlined in Section 2 of this manual.
  4.  
  5. Remove the drive belt tensioner.
  6.  
  7. Remove the EGR valve outlet pipe.
  8.  
  9. 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.
  10.  

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.
  2.  



Click image to see an enlarged view

Fig. Exploded view of the upper and lower intake manifold and gaskets - 1995 3.8L (VIN K) engine



Click image to see an enlarged view

Fig. Intake manifold bolt tightening sequence - 1996-97 3.8L (VIN K) engine; VIN 1 similar

  1. Install the EGR valve outlet pipe.
  2.  
  3. Install the drive belt tensioner.
  4.  
  5. Install the alternator.
  6.  
  7. Connect the upper radiator hose.
  8.  
  9. Position the upper intake manifold on the lower manifold. Install the retaining bolts and tighten to 89 inch lbs. (10 Nm).
  10.  
  11. Install the throttle body support bracket, then connect the throttle cable.
  12.  
  13. Install the cable bracket-to-cylinder head mounting bolt.
  14.  
  15. Install the EGR heat shield.
  16.  
  17. Install the fuel rail.
  18.  
  19. Install the manifold vacuum source.
  20.  
  21. Connect the right side spark wires on the right side of the engine.
  22.  
  23. Install the fuel injector sight shield and air intake duct.
  24.  
  25. Fill the cooling system with the proper type and amount of fluid.
  26.  
  27. Connect the negative battery cable. Start the engine and check for leaks. Check the cooling system, and add as necessary.
  28.  

 
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