Question about 1996 Ford Thunderbird LX

1 Answer

Intake manifold cracked and leacking coolant (External)

There is a hairline crack about a 1/2 inch long on the neck of the intake manifold where the hose from the heating system connects to the intake manifold. The small crack in the manifold has caused a coolant leak which has damaged the spark plug wire located right underneath it, which in turn is causing it to misfire. Can i repair the crack using JB Weld? Or do i need to buy a new intake manifold entirely? Its just a small little crack.

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You can clean the area really good with degreaser and apply JB Weld but that is only a temporary fix it will leak again

Posted on Oct 04, 2009

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Posted on Jan 02, 2017

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1 Answer

How to replace the fuel injector for a 2008 chrysler pt cruiser?


To remove a fuel injector or injectors you must remove the fuel supply rail that sits over them. Here is how you do that for both engine options, Turbo and non Turbo..

Removal & Installation

Except Turbocharged Models

WARNING Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle. This may result in personal injury or *****.
  1. Release fuel system pressure.
  2. Remove the air cleaner lid, disconnect the inlet air temperature sensor and makeup air hose.
  3. Remove the negative battery cable.
  4. Remove the engine cover or throttle control shield if equipped.
    NOTE Wrap shop towels around hose to catch any gasoline spillage.
  5. Disconnect fuel supply tube from rail.
  6. Remove the Intake Manifold, refer to the Engine section.
  7. Disconnect electrical connectors from fuel injectors.
  8. Remove bolts holding fuel rail.
  9. Remove the fuel rail and injectors.
  10. Remove the injectors from the fuel rail.
To install:
  1. Install injectors to the fuel rail.
  2. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.
  3. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place. Tighten fuel rail bolts to 170-230 inch lbs. (19.5-25.5 Nm).
  4. Attach electrical connectors to fuel injectors.
  5. Connect fuel supply tube to fuel rail. Refer to Quick Connect Fittings in the Fuel Delivery section
  6. Install Intake Manifold, refer to the Engine section.
  7. Install the engine cover or throttle control shield if equipped.
  8. Install the negative battery cable.
  9. Install the air cleaner lid, connect the inlet air temperature sensor and makeup air hose. Tighten air inlet tube clamps to 20-30 inch lbs. (2-4 Nm).

Turbocharged Models

WARNING Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle. This may result in personal injury or *****.
  1. Release the fuel system pressure.
  2. Disconnect the negative battery cable.
  3. Disconnect the throttle body inlet hose and remove from throttle body.
  4. Disconnect the purge hose from the throttle body.
  5. Unlock and disconnect the electrical connection at the throttle body.
  6. Remove the throttle control shield .
  7. Remove the throttle and speed control cables from the throttle body.
  8. Remove the cables from the throttle body bracket.
  9. Unlock and disconnect the MAP sensor electrical connector.
  10. Remove the vacuum lines from the rear of the intake manifold.
  11. Remove the 5 bolts from the front of the intake manifold.
  12. Remove the 2 bolts from the rear of the intake manifold.
  13. Remove the intake manifold. Cover the lower intake manifold openings.
  14. Drain the Coolant system.
  15. Move the upper radiator hose clamp, so that the hose can be rotated up and out of the way.
  16. Remove the 2 small hoses from the thermostat housing.
  17. Remove the 2 bolts from the thermostat housing and rotate the assembly up and out of the way.
    NOTE Wrap shop towels around hose to catch any gasoline spillage.
  18. Disconnect the fuel line from the fuel rail.
  19. Unlock and disconnect the electrical connectors from the fuel injectors.
  20. Remove the wiring harness from the fuel rail.
  21. Remove the 2 bolts from the fuel rail.
  22. Remove the fuel rail and injectors from the intake manifold.
To install:
  1. Install the fuel injectors to the fuel rail.
  2. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.
  3. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place.
  4. Install the 2 bolts to the fuel rail. Tighten fuel rail bolts to 170-230 inch lbs. (19.5-25.5 Nm).
  5. Install the wiring harness to the fuel rail.
  6. Connect and lock the electrical connectors to the fuel injectors.
  7. Connect the fuel line to the fuel rail.
  8. Rotate the assembly back into place and install the 2 bolts to the thermostat housing tighten to 110 inch lbs. (12.5 Nm).
  9. Move the upper radiator house clamp back into place.
  10. Install the 2 small hoses to the thermostat housing.
  11. Fill the Coolant system.
  12. Install the intake manifold.
  13. Install the 2 bolts to the rear of the intake manifold tighten to 250 inch lbs. (28 Nm).
  14. Install the 5 bolts to the front of the intake manifold and tighten to 250 inch lbs. (28 Nm).
  15. Install the vacuum lines to the rear of the intake manifold.
  16. Connect and lock the MAP sensor electrical connector.
  17. Install the cables to the throttle body bracket.
  18. Install the throttle and speed control cables to the throttle body.
  19. Install the throttle control shield.
  20. Connect and lock the electrical connections at the throttle body.
  21. Connect the purge hose to the throttle body.
  22. Connect the throttle body inlet hose to the throttle body and tighten clamps to 20-30 inch lbs. (2-4 Nm).
  23. Connect the negative battery cable.
  24. Use the DRB® scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.

Mar 02, 2017 | Chrysler Cars & Trucks

1 Answer

How to replace the fuel injector on a 2008 chrysler pt cruiser


Removal & Installation

Except Turbocharged Models

WARNING Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle. This may result in personal injury or *****.
  1. Release fuel system pressure.
  2. Remove the air cleaner lid, disconnect the inlet air temperature sensor and makeup air hose.
  3. Remove the negative battery cable.
  4. Remove the engine cover or throttle control shield if equipped.
    NOTE Wrap shop towels around hose to catch any gasoline spillage.
  5. Disconnect fuel supply tube from rail.
  6. Remove the Intake Manifold, refer to the Engine section.
  7. Disconnect electrical connectors from fuel injectors.
  8. Remove bolts holding fuel rail.
  9. Remove the fuel rail and injectors.
  10. Remove the injectors from the fuel rail.
To install:
  1. Install injectors to the fuel rail.
  2. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.
  3. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place. Tighten fuel rail bolts to 170-230 inch lbs. (19.5-25.5 Nm).
  4. Attach electrical connectors to fuel injectors.
  5. Connect fuel supply tube to fuel rail. Refer to Quick Connect Fittings in the Fuel Delivery section
  6. Install Intake Manifold, refer to the Engine section.
  7. Install the engine cover or throttle control shield if equipped.
  8. Install the negative battery cable.
  9. Install the air cleaner lid, connect the inlet air temperature sensor and makeup air hose. Tighten air inlet tube clamps to 20-30 inch lbs. (2-4 Nm).

Turbocharged Models

WARNING Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle. This may result in personal injury or *****.
  1. Release the fuel system pressure.
  2. Disconnect the negative battery cable.
  3. Disconnect the throttle body inlet hose and remove from throttle body.
  4. Disconnect the purge hose from the throttle body.
  5. Unlock and disconnect the electrical connection at the throttle body.
  6. Remove the throttle control shield .
  7. Remove the throttle and speed control cables from the throttle body.
  8. Remove the cables from the throttle body bracket.
  9. Unlock and disconnect the MAP sensor electrical connector.
  10. Remove the vacuum lines from the rear of the intake manifold.
  11. Remove the 5 bolts from the front of the intake manifold.
  12. Remove the 2 bolts from the rear of the intake manifold.
  13. Remove the intake manifold. Cover the lower intake manifold openings.
  14. Drain the Coolant system.
  15. Move the upper radiator hose clamp, so that the hose can be rotated up and out of the way.
  16. Remove the 2 small hoses from the thermostat housing.
  17. Remove the 2 bolts from the thermostat housing and rotate the assembly up and out of the way.
    NOTE Wrap shop towels around hose to catch any gasoline spillage.
  18. Disconnect the fuel line from the fuel rail.
  19. Unlock and disconnect the electrical connectors from the fuel injectors.
  20. Remove the wiring harness from the fuel rail.
  21. Remove the 2 bolts from the fuel rail.
  22. Remove the fuel rail and injectors from the intake manifold.
To install:
  1. Install the fuel injectors to the fuel rail.
  2. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.
  3. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place.
  4. Install the 2 bolts to the fuel rail. Tighten fuel rail bolts to 170-230 inch lbs. (19.5-25.5 Nm).
  5. Install the wiring harness to the fuel rail.
  6. Connect and lock the electrical connectors to the fuel injectors.
  7. Connect the fuel line to the fuel rail.
  8. Rotate the assembly back into place and install the 2 bolts to the thermostat housing tighten to 110 inch lbs. (12.5 Nm).
  9. Move the upper radiator house clamp back into place.
  10. Install the 2 small hoses to the thermostat housing.
  11. Fill the Coolant system.
  12. Install the intake manifold.
  13. Install the 2 bolts to the rear of the intake manifold tighten to 250 inch lbs. (28 Nm).
  14. Install the 5 bolts to the front of the intake manifold and tighten to 250 inch lbs. (28 Nm).
  15. Install the vacuum lines to the rear of the intake manifold.
  16. Connect and lock the MAP sensor electrical connector.
  17. Install the cables to the throttle body bracket.
  18. Install the throttle and speed control cables to the throttle body.
  19. Install the throttle control shield.
  20. Connect and lock the electrical connections at the throttle body.
  21. Connect the purge hose to the throttle body.
  22. Connect the throttle body inlet hose to the throttle body and tighten clamps to 20-30 inch lbs. (2-4 Nm).
  23. Connect the negative battery cable.
  24. Use the DRB® scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.

Mar 02, 2017 | Chrysler Cars & Trucks

1 Answer

Evap problem


code p0440 refers to EVAP system malfunction==causes hose connections---intake leak---EVAP canister purge valve

check for vacuum leaks (vents -auto control-manifold-brake booster etc). Check for cracked /loose hoses on the tank/filler neck

Sep 06, 2014 | 2002 Toyota Corolla

1 Answer

Where is thermostat on 2004 chrysler concorde 2.7 liter engine


Follow the upper radiator hose from the radiator back to where it connects to the intake manifold whare the hose clamp is . The part the hose attaches to is called the goose neck the Tstat is located under this part usealy 2 or 3 bolts hold it on but it is a water seal so you will need a new gasket for it , Cleaning the surfaces that mate together is vary important to get a good seal gasket sealer can help but the cleaning is more important and don't try to over tighten the bolts you may crack the goose neck . The torque is likely 12 to 18 ftlbs max . Check the condution of the antifreeze this cause most of the problems with over heating and every 5 years or so you need to replace the antifreeze Hope it works Tstat is not expensive or that difficult to do

Jun 01, 2011 | Chrysler Concorde Cars & Trucks

1 Answer

What is the torque specs on intake 4.3 l v6 vortec


0900c1528008ee89.gif

To install:

  1. Clean all gasket surfaces completely.
  2. Install the intake manifold gaskets with the port blocking plates facing the rear of the engine. Factory gaskets should have the words "This Side Up" visible.
  3. Apply gasket sealer to the front and rear sealing surfaces of the engine block.
  4. Apply a 0.197 inch (5mm) bead of RTV sealer to the front and rear of the block. Extend the sealer approximately 1 / 2 -inch (13mm) onto the heads.
  5. Install the lower intake manifold.
  6. Apply sealer to the lower intake manifold bolts prior to installation.
  7. Install the bolts and tighten in sequence and in 3 steps as follows:
    1. First step to 26 inch lbs. (3 Nm).
    2. Second step to 106 inch lbs. (12 Nm).
    3. Final step to 11 ft. lbs. (15 Nm).

  8. If removed, install the alternator bracket bolt.
  9. Install the coolant by-pass hose.
  10. Install the EGR valve.
  11. Connect the upper radiator hose to the thermostat housing.
  12. Connect the heater hose to the lower intake manifold.
  13. Connect the fuel pressure and return lines to the lower intake manifold.
  14. Connect the wiring harnesses and brackets to the lower manifold.
  15. Install the throttle cable bracket, then attach the throttle cable and the cruise control cable (if equipped).
  16. Install the transmission oil level indicator and tube, if equipped.
  17. Install the EGR tube, clamp and bolt.
  18. Install the PCV valve and hose.
  19. Install the A/C compressor and bracket.
  20. Install the distributor.
  21. Install the upper intake manifold.
  22. Fill the cooling system.
  23. Connect the negative battery cable.
  24. Start the vehicle and check the ignition timing (not adjustable).
  25. Verify no oil, coolant, vacuum or fuel leaks.

    0900c1528008ee88.gif

  26. Install the intake manifold bolts and tighten them to 35 ft. lbs. (48 Nm) in the sequence shown.

May 09, 2011 | Chevrolet TrailBlazer Cars & Trucks

1 Answer

Starter needs to be replaced. Need instruction procedure for a do it yourselfer.


Hi, I have pasted the procedure from autozone.com below. Because this requires removal of the intake manifold, please be as sure as possible that your starter needs replacement. If you have any doubt, please let me know what your symptoms are and what troubleshooting you have done that led you to believe your starter is bad. Also, if you have any questions about the procedure below, please let me know. Thanks for using FixYa.


Removal & Installation


Disconnect the Negative battery cable


Relieve the fuel system pressure (you can do this by placing a rag over the schrader valve on the fuel rail and pressing in the valve stem--just be careful not to spray fuel on your eyes).


Drain the cooling system.


Remove or disconnect the following:


  • Intake manifold heat shield
  • Sight shield
  • Coil module connectors from the coil modules located on the valve covers
  • Positive Crankcase Ventilation (PCV) hose and valve from the valve cover
  • Fuel regulator vacuum tube
  • Vacuum tubes from the AIR solenoid
  • Fuel inlet and return lines
  • Fuel rail bracket retaining nut at the rear lift bracket
  • 2 pushnuts attaching the engine coolant heater wire and set it aside, if equipped
  • Fuel injector electrical connections
  • Fuel rail and injectors
  • Plenum duct clamp at the rear of the intake manifold, loosen
  • Intake manifold bolts and the manifold
Clean the manifold mating surfaces.


Remove or disconnect the following:
Starter electrical connectors Starter motor

jturcotte_1382.gif


Fig. View of starter motor removal and wires



To install:

Install or connect the following:

  • -S- terminal wire. Torque the nut to 35 inch lbs. (4 Nm).
  • Starter electrical connectors. Torque the nut to 89 inch lbs. (10 Nm).
  • Starter motor
  • Mounting bolts. Torque the bolts to 22 ft. lbs. (30 Nm).


jturcotte_1383.gif


Fig. Intake manifold torque sequence- 4.6L engines

  1. Grease the inside edge of the rubber plenum duct.
  2. Position the intake manifold by performing the following sub-steps:
    1. Place the rear of the intake manifold into the plenum duct.
    2. Place the front of the intake manifold downward on to the cylinder heads.

  3. Install the intake manifold bolts and torque to 89 inch lbs. (10 Nm) in the sequence illustrated. DO NOT torque the intake manifold bolts when the engine is HOT or at operating temperature.
  4. Make sure the plenum duct is fully attached to the rear of the intake manifold and tighten the plenum duct clamp to 20 inch lbs. (2.25 Nm).
  5. Install or connect the following:

    Fuel rail and injectors and tighten the rail retainers to 89 inch lbs. (10 Nm) Fuel injector electrical connections Alternator coolant pipe/surge tank pipe and position onto the fuel rail studs Engine coolant heater wire onto the studs and install the pushnuts, if equipped Fuel rail bracket retaining nut at the rear lift bracket and tighten to 89 inch lbs. (10 Nm) Fuel inlet and return lines Vacuum tubes to the AIR solenoid Fuel regulator vacuum tube Positive Crankcase Ventilation (PCV) valve and hose to the valve cover Coil module connectors to the coil modules located on the valve covers Sight shield Intake manifold heat shield Negative battery cable
  6. Fill and bleed the cooling system.

Mar 31, 2011 | 2002 Cadillac Deville

4 Answers

My starter gave out yesterday. I didnt know it was inside the intake manifold. Either way i started the job last night, i am having a hard time pulling out the manifold. I already loosened the clamp but i...


Hi!!
These are the steps to follow to remove the Starter Motor and the Intake Manifold. If you follow them you'll have no problems when the job is done. Pay special attention to the pre-installation steps for the Intake Manifold.

To Replace the Starter, Remove or disconnect the following:
  1. Negative battery cable
  2. Intake manifold
  3. Starter electrical connectors
  4. Starter motor
View of starter motor removal and wires
1kbron_11.jpg

To install, Install or connect the following:
  1. -S- terminal wire. Torque the nut to 35 inch lbs. (4 Nm).
  2. Starter electrical connectors. Torque the nut to 89 inch lbs. (10 Nm).
  3. Starter motor
  4. Mounting bolts. Torque the bolts to 22 ft. lbs. (30 Nm).
  5. Intake manifold
  6. Negative battery cable

INTAKE MANIFOLD
PRIOR TO REMOVAL:
  • Relieve the fuel system pressure
  • Drain the cooling system.

Remove or disconnect the following:
  1. Negative battery cable
  2. Intake manifold heat shield
  3. Sight shield
  4. Coil module connectors from the coil modules located on the valve covers
  5. Positive Crankcase Ventilation (PCV) hose and valve from the valve cover
  6. Fuel regulator vacuum tube
  7. Vacuum tubes from the AIR solenoid
  8. Fuel inlet and return lines
  9. Fuel rail bracket retaining nut at the rear lift bracket
  10. 2 pushnuts attaching the engine coolant heater wire and set it aside, if equipped
  11. Fuel injector electrical connections
  12. Fuel rail and injectors
  13. Plenum duct clamp at the rear of the intake manifold, loosen Intake manifold bolts and the manifold
  14. Clean the manifold mating surfaces.
Intake manifold torque sequence- 4.6L engines

1kbron_12.jpg


PRIOR TO INSTALL:
  • Grease the inside edge of the rubber plenum duct.
  • Position the intake manifold by performing the following sub-steps:
  • Place the rear of the intake manifold into the plenum duct.
  • Place the front of the intake manifold downward on to the cylinder heads.
  • Install the intake manifold bolts and torque to 89 inch lbs. (10 Nm) in the sequence illustrated. DO NOT torque the intake manifold bolts when the engine is HOT or at operating temperature.
  • Make sure the plenum duct is fully attached to the rear of the intake manifold and tighten the plenum duct clamp to 20 inch lbs. (2.25 Nm).

Install or connect the following:
  1. Fuel rail and injectors and tighten the rail retainers to 89 inch lbs. (10 Nm)
  2. Fuel injector electrical connections
  3. Alternator coolant pipe/surge tank pipe and position onto the fuel rail studs
  4. Engine coolant heater wire onto the studs and install the pushnuts, if equipped
  5. Fuel rail bracket retaining nut at the rear lift bracket and tighten to 89 inch lbs. (10 Nm)
  6. Fuel inlet and return lines
  7. Vacuum tubes to the AIR solenoid
  8. Fuel regulator vacuum tube
  9. Positive Crankcase Ventilation (PCV) valve and hose to the valve cover
  10. Coil module connectors to the coil modules located on the valve covers
  11. Sight shield
  12. Intake manifold heat shield
  13. Negative battery cable
  14. Fill and bleed the cooling system.
Good Luck!! A HELPFUL - 4 THUMBS - rating for this solution would be greatly appreciated. Thank you for using FixYa.

Nov 11, 2010 | 2001 Cadillac DeVille

1 Answer

Torque sequence for 1996 chevrolet van intake manifold with a 4.3 litre moter


Ha, you tried to fool me with the bit about a 3.5 L motor--I could find that one...here is the complete procedure from AutoZone.com:




Installation To install:
  1. Clean the gasket mounting surfaces. Be sure to inspect the manifold for warpage and/or cracks. If necessary, replace it.
  2. Position the gaskets on the cylinder head with the port blocking plates to the rear and the This Side Up stamps facing upward. Then apply a 3 / 16 in. (5mm) bead of RTV sealant on the front and rear of the engine block at the block-to-manifold mating surface. Extend the bead 1 / 2 in. (13mm) up each cylinder head to seal and retain the gaskets.

    0996b43f80208c7b.jpg enlarge_icon.gifenlarge_tooltip.gif Fig. Lower intake manifold tightening sequence-4.3L engines
  3. Install the lower intake manifold. Tighten the bolts in sequence and in 3 steps, as follows:


    1. Step 1: 26 inch lbs. (3 Nm).
    2. Step 2: 106 inch lbs. (12 Nm).
    3. Step 3: 133 inch. lbs. (15 Nm).

  4. Install or connect the following:

    Power steering pump Alternator bracket bolt near the thermostat housing Wiring harness to the lower manifold components, including the injector, EGR valve and ECT sensor Air conditioning compressor bracket-to-the lower intake manifold pencil braces
  5. Install transmission oil dipstick tube, if necessary.

    Fuel supply and return lines to the rear of the lower intake
  6. Temporarily reattach the negative battery cable, then pressurize the fuel system (by cycling the ignition without starting the engine) and check for leaks.
  7. Disconnect the negative battery cable.
  8. Install or connect the following:

    Heater hose to the lower intake Upper radiator hose to the thermostat housing Distributor assembly and engage the wiring Ignition coil Connect vacuum hoses to the upper and lower intake manifold. New upper intake manifold gasket, making sure the green sealing lines are facing upward Upper intake manifold Manifold retainers. Tighten them to 88 inch lbs. (10 Nm) using two passes. Purge solenoid and bracket Brake booster vacuum hose at the upper intake manifold PCV hose to the rear of the upper intake manifold Vacuum hoses to both the front and rear of the manifold assembly Throttle body Throttle linkage to the upper intake Wiring to the upper intake components including the TP sensor, IAC motor, MAP sensor and the fuel meter Engine cover Air intake assembly
  9. Connect negative battery cable.
  10. Refill the engine cooling system.
  11. Start the engine and check for leaks.

Aug 26, 2010 | 1996 Chevrolet Astro

2 Answers

I have a 98 lincoln town car executive and I need to know how you change the thermostat


1. drain coolant
2. remove engine cover
3. remove the 2 bolts from water hose connection (upper rad hose connecting to)
4. remove o-ring and thermostat
5. repeat in reverse order

Feb 05, 2010 | 1998 Lincoln Continental

2 Answers

Pontiac bonneville 3.8 vin code k . I replaced the in take gasket because it was leaking water between the top an bottom intakes going into the cyclinder heads its still leaking after all this work ive...


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.

Oct 18, 2009 | 1995 Pontiac Bonneville

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