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17 years GM tech
17 years GM tech, GM master tech
Category: Pontiac
Satisfied Customers: 1918
Experience:  25 years automotive experience, 15 years with Saturn
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99 Pontiac Grand Am: I replace the Lower Intake Manifold Gasket on my

Resolved Question:

How do I replace the Lower Intake Manifold Gasket on my '99 Pontiac Grand Am 3.4 L??
Submitted: 3 years ago.
Category: Pontiac
Expert:  17 years GM tech replied 3 years ago.

17 years GM tech :

Hello and thank you for your post. I am a master certified GM tech and can help you to resolve your issue.

17 years GM tech :


  1. Before servicing the vehicle, refer to the precautions section.




  2. Relieve the fuel system pressure.




  3. Drain the cooling system.




  4. Remove or disconnect the following:




    • Air cleaner assembly




    • Accessory drive belt




    • Exhaust Gas Recirculation (EGR) valve




    • Brake vacuum pipe at the intake plenum




    • Fuel pressure regulator vacuum line




    • Spark plug wires from the spark plugs and the intake plenum retainers




    • Ignition coil assembly and the Evaporative Emissions (EVAP) canister purge solenoid as an assembly




    • Throttle Position Sensor (TPS) electrical connector




    • Idle Air Control (IAC) sensor electrical connector




    • Fuel injector electrical connectors




    • Engine Coolant Temperature (ECT) sensor electrical connector




    • Camshaft Position (CMP) sensor electrical connector




    • Vacuum modulator




    • Manifold Absolute Pressure (MAP) sensor




    • Coolant hoses from the throttle body




    • Control cables from the throttle body and intake plenum bracket




    • Upper intake plenum




    • Both rocker arm covers




    • Fuel lines from the fuel rail and fuel line bracket




    • Fuel rail with the injectors




    • Inlet cooling pipe from the outlet housing




    • Heater bypass hose from the water pump and the cylinder head




    • Upper radiator hose at the thermostat housing




    • Thermostat housing




    • Lower intake manifold




     











    NOTE

    When removing the valvetrain components, keep them in order for installation purposes.



    The pushrods are different lengths and if mixed up will cause mechanical damage to the camshafts and pushrods and lifters

     




    • Rocker arms and pushrods






To install:














[IMAGE][SRC][/SRC][ALT]Exploded view of the upper and lower intake—3.1L & 3.4L engines[/ALT][WIDTH]100[/WIDTH][HEIGHT]100[/HEIGHT][STYLE][/STYLE][/IMAGE]

Exploded view of the upper and lower intake—3.1L & 3.4L engines


Click to Enlarge













[IMAGE][SRC][/SRC][ALT]Lower intake manifold tightening sequence—3.1L & 3.4L engines[/ALT][WIDTH]100[/WIDTH][HEIGHT]100[/HEIGHT][STYLE][/STYLE][/IMAGE]

Lower intake manifold tightening sequence—3.1L & 3.4L engines


Click to Enlarge

 




  1. Place a 3mm bead of RTV, on each ridge, where the front and rear of the intake manifold contact the block.




  2. Install or connect the following:




    • New intake manifold gasket




    • Pushrods and rocker arms. Torque the bolts to 89 inch lbs. (10 Nm) plus an additional 30 degree turn.




    • Lower intake manifold. Apply sealant to the threads of the bolts and torque the bolts to 115 inch lbs. (13 Nm).




     











    WARNING

    In order to prevent oil leaks at the intake manifold, tighten the vertical bolts before the diagonal bolts.



     




    • Thermostat housing with a new gasket. Torque the bolts to 19 ft. lbs. (26 Nm).




    • Upper radiator hose at thermostat housing




    • Coolant bypass hose to the water pump and the cylinder head




    • Coolant inlet pipe to coolant outlet housing




    • Fuel rail with the injectors




    • Fuel lines to the fuel rail and fuel line bracket




    • Both rocker arm covers. Torque the bolts to 89 inch lbs. (10 Nm).




    • Upper intake manifold with a new gasket. Torque the bolts to 18 ft. lbs. (25 Nm).




    • Coolant hoses to the throttle body




    • MAP sensor




    • Vacuum modulator




    • CMP sensor electrical connector




    • ECT sensor electrical connector




    • Fuel injector electrical connectors




    • IAC sensor electrical connector




    • TPS electrical connector




    • Ignition coil assembly and the EVAP canister purge solenoid as an assembly




    • Spark plug wires




    • Fuel pressure regulator vacuum line




    • EGR valve. Torque the bolts to 22 ft. lbs. (30 Nm).




    • Control cables to the throttle body and intake plenum bracket




    • Brake vacuum pipe at the intake plenum




    • Accessory drive belt




    • Air cleaner assembly




    • Negative battery cable






  3. Refill the cooling system.


     











    NOTE

    An engine oil and filter change is recommended.



     




  4. Start the vehicle and verify no leaks.




 

17 years GM tech :

hope this helps.

17 years GM tech :

It is also reccomended to replace the oil pump drive shaft o ring when this is apart. It is located at the rear of the engine near the trans. It is held in with one bolt and clamp. Remove the clamp and pop the drive out. The o ring on that leaks all the time.

17 years GM tech :

It is also helpful to use a center punch and dimple the seal area at the engine front and rear of the intake so when you put the rtv sealant there, it has a rough surface to grab.

17 years GM tech :

For the rtv I reccomend using permatex "right stuff" works better than anything on the market.

17 years GM tech :

Good luck

17 years GM tech :

read this over and if you have any q's let me know

17 years GM tech :

the pushrods are installed above and below the intake side gaskets so you do need to remove them to replace the gasket.

17 years GM tech :

Buy the entire kit which comes with all the gaskets you need, then buy the drive o ring and the right stuff sealant and a gallon of DexCool antifreeze. (no substitution there!)

17 years GM tech :

if any of the coolant pipes are installed in a quick disconnect style of connector, replace the entire fitting. They ar ereadily available and sometimes crack from corrosion. You do not want to remove this intake again for that

17 years GM tech :

If there are o-rings instead, and they do not come with the kit, replace the orings as well.

Customer :

Can you please send me also the list of tools needed to do this job, thanks

17 years GM tech :

that will require a set of 1/4" and 3/8" metric sockets and extensions, screw drivers and prybars.

17 years GM tech :

A basic mechanics tool set plus some gasket scrapers, sand paper, brake cleaner spray, rags etc...

17 years GM tech :

you will need a few metric wrenches as well so basically all the basic metric tools in a beginners tool set plus some long extensions.

17 years GM tech :

I usually use a 1/4" universal swivel on some of the lower intake bolts for clearance as well.

17 years GM tech :

pliers and the such will come in handy as well

Customer :

OK, thanks. also wondering what do i look at under the Chilton Repair content

17 years GM tech :

what do you mean?

17 years GM tech :

The info I sent you was from chilton online but it is a password XXXXX website

Customer :

above it says to click to enlarge image...

Customer :

or is that the info below

17 years GM tech :

That is the image below

Customer :

ah thanks

17 years GM tech :

Those are the only images below

17 years GM tech :

Your welcome

17 years GM tech :

is there anythinh else tonight?

Customer :

ok so i have someone who is a mechanic looking at this for me & he would like to see whats involved in the process of doing this wonderful task. if he has any questions how do i get back to you or do I have to pay again???

17 years GM tech :

You can reply to this thread within a few days with no additional payment.

17 years GM tech :

Once the thread closes you will have to open a new thread unless you can manually re-open the thread.

17 years GM tech :

If you have the option to manually re-open the thread then I can answer questions related to this repair for no charge

17 years GM tech :

If not then it will be considered a new question.

17 years GM tech :

if you are satisfied with my answers tonight, please hit the accept button and please also give me feedback on our session.

Customer :

so can I leave this open for a bit or do I have to close it down once i'm done??

Customer :

ha ha i'll be satisfied if he can fix my poor car... kidding thatnk you so much

17 years GM tech :

I prefer that you hit accept since i have answered your question. I suggest posting a "poke" every day or 2 until you no longer need me ( short post about the status of your repair)

17 years GM tech :

Once done the system will see no action and then the question will be closed.

17 years GM tech :

I believe it takes a few days with no action before it closes.

Customer :

ok so accept, then how do i 'poke' you after that

17 years GM tech :

Just post a short comment like..."still waiting for mechanic..."

17 years GM tech :

That will keep the thread active

Customer :

where? do i do this

Customer :

on here

Customer :

i've never done this before

17 years GM tech :

same place you are right now. Once you log off you should get an email with a link to this question. Click th elink to come back here any time

17 years GM tech :

I am online daily off and on so I may not respond immediately but I will within a day for sure

Customer :

ah awesome, once again thank you very much I sure hope my car gets fixed \

17 years GM tech :

I have only been in the chat room as an expert, not as a customer so I am not sure what buttons you have but I am pretty sure you can manually reopen a post if it closes.

17 years GM tech :

Thanks, XXXXX XXXXX and good night.


 

Customer :

have a good evening to you also, thanks again :)

17 years GM tech, GM master tech
Category: Pontiac
Satisfied Customers: 1918
Experience: 25 years automotive experience, 15 years with Saturn
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