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Pontiac Master
2,993 Answers
- Posted on Oct 18, 2009
Re: Pontiac bonneville 3.8 vin code k . I replaced the in...
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.
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Properly relieve the fuel system pressure, as outlined in Section 5 of this manual.
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Disconnect the negative battery cable.
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Drain the cooling system into a suitable container.
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Remove the fuel injector sight shield and air intake duct.
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Tag and disconnect the spark plug wires on the right side of the engine and position aside.
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Remove the manifold vacuum source.
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Remove the fuel rail.
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Remove the EGR heat shield.
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Unfasten the cable bracket-to-cylinder head mounting bolt.
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Disconnect the throttle cable.
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Remove the throttle body support bracket.
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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.
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Disconnect the upper radiator hose.
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Remove the alternator, as outlined in Section 2 of this manual.
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Remove the drive belt tensioner.
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Remove the EGR valve outlet pipe.
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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:
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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.
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Install the EGR valve outlet pipe.
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Install the drive belt tensioner.
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Install the alternator.
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Connect the upper radiator hose.
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Position the upper intake manifold on the lower manifold. Install the retaining bolts and tighten to 89 inch lbs. (10 Nm).
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Install the throttle body support bracket, then connect the throttle cable.
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Install the cable bracket-to-cylinder head mounting bolt.
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Install the EGR heat shield.
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Install the fuel rail.
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Install the manifold vacuum source.
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Connect the right side spark wires on the right side of the engine.
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Install the fuel injector sight shield and air intake duct.
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Fill the cooling system with the proper type and amount of fluid.
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Connect the negative battery cable. Start the engine and check for leaks. Check the cooling system, and add as necessary.
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