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How to Replace Intake Manifold Gasket 99-03 Pontiac Grand Am PART 2

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How to Replace Intake Manifold Gasket 99-03 Pontiac Grand Am PART 2

Created on: 2013-09-27

This video will show you how to replace the intake manifold gasket on your 99-05 Pontiac Grand Am. Part 2.

  1. step 1 :Beginning the Repair
    • This is Part 2 of a three-part video
    • Please consult Part 1 for prior instructions
    • Perform the steps outlined in Part 1
  2. step 2 :Cleaning the Valve Covers
    • Remove the gasket/RTV between the heads with a razor blade
    • Clean the valve covers and intake manifold with parts washer and degreaser
  3. step 3 :Installing the Lower Intake Manifold
    • Align the pushrods with the manifold gaskets
    • Align the pushrods in the gaskets and tighten the rockers with a 10mm socket
    • Tighten the rocker bolts to 14 newton meters plus thirty degrees or ten foot-pounds with a torque wrench and thirty degrees with a 10mm wrench
    • Attach the gaskets between the heads with RTV on both sides
    • Have an assistant pull back the fuel injectors
    • Set the lower intake manifold down into place
    • Replace eight 10mm bolts on the lower intake manifold
    • Tighten the upper bolts to 13 newton meters and the lower bolts to 25 newton meters
  4. step 4 :Installing the Valve Covers
    • Place the gasket on the valve cover
    • Put the valve cover on
    • Tighten and replace the 8mm bolts
    • Repeat the process for the back side
  5. step 5 :Installing the Coolant Pipe
    • Remove the o-ring on the coolant pipe
    • Scrape at the pipe to clean it
    • Place the new o-ring on the pipe
    • Place the pipe down into place and replace the bolts to hold it in place
  6. step 6 :Installing the Coolant Hoses
    • Scrape dried coolant from the coolant pipe with a wire brush
    • Connect the coolant hose
    • Slide the clamp on with a pair of pliers
    • Repeat the process for the other side
  7. step 7 :Installing the Tensioner
    • Feed the tensioner and alternator pulleys down into place
    • Replace the 15mm bolt to the alternator
    • Replace the 16mm bolt from the tensioner
    • Replace 15mm bolt beneath the idler pulley
  8. step 8 :Installing the Alternator
    • Put the power steering pulley down into place
    • Tighten the 13mm bolts to secure the steering pulley
    • Connect the alternator harness
    • Replace the 13mm bolt to the alternator
    • Connect the rubber boot
    • Insert the three 15mm bolts on the alternator
    • Place the alternator in place
    • Tighten the 15mm bolts
    • Replace the 18mm bolt beneath the steering pulley
  9. step 9 :Installing the Fuel Injectors
    • Insert the fuel injector harnesses into place by their appropriate number
    • Line up the fuel injectors and push them down into the manifold
    • Replace the 10mm bolts on the fuel injectors
    • Connect the alternator harness
    • Connect the other harness on the other side of the manifold
    • Place the new gaskets on the intake manifold
  10. step 10 :Installing the Coolant Hose
    • Scrape off the old o-ring from the coolant tube
    • Place the new o-ring on the coolant tube
    • Push the hose into the manifold
  11. step 11 :Installing the Upper Intake Manifold Plenum
    • Replace the 10mm bolt below the right side of the intake manifold
    • Replace the 13mm nut on the lower part of the intake manifold
    • Insert the upper intake manifold plenum into place
    • Insert the 10mm bolts from the upper intake plenum
    • Insert the 13mm nut from the upper intake plenum
    • Torque the 10mm bolts to 18 foot-pounds
  12. step 12 :Installing the MAP Sensor and Throttle Body
    • Insert the two 7mm bolts from the back of the MAP sensor bracket
    • Connect the MAP sensor to the lead
    • Connect the sensor to the intake manifold
    • Tighten the 7mm bolts to the MAP sensor
    • Insert the 10mm bolts from the top of the coil pack
    • Insert the 13mm bolts from the bottom of the coil pack
    • Insert the hose and hose clamp on the back of the intake manifold
    • Insert the vacuum hoses to the intake manifold
    • Remove the rubber plug on the old manifold plenum to the new one
    • Tighten the two 13mm bolts from the throttle body
    • Tighten the 10mm bolts from the throttle body bracket
  13. step 13 :Installing the EGR Valve
    • Slide the hoses onto the coolant line
    • Tighten the hoses with the clamp and pliers
    • Place the gasket below the EGR
    • Insert the EGR and tighten the 10mm bolts

Tools needed for replacement

  • General Tools

    Assistant

    Drain Pan

    Flashlight

    Funnel

    Putty Knife

    Razor Blade / Gasket Scraper

    Wire Brush

  • Materials, Fluids, and Supplies

    RTV

  • Pliers, Cutters & misc Wrenches

    Needle nose pliers

  • Ratchets & Related

    3/8 Inch Drive Ratchet

    Socket Extensions

    Swivel

    Torque Wrench

  • Screwdrivers & Related

    Flat Blade Screwdriver

    Phillips Head Screwdriver

  • Sockets - Metric

    10mm Socket

    13mm Socket

    15mm Socket

    16mm Socket

    18mm Socket

    7mm Socket

Installation Video
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Brought to you by 1AAuto.com, your source for quality replacement parts and the best service on the Internet.

Hi, I'm Mike from 1A Auto. I hope this how-to video helps you out, and next time you need parts for your vehicle, think of 1AAuto.com. Thanks.

This video is part two of a three part series. We are replacing the lower intake manifold gaskets on a 3.4-liter V6 in this Grand Am. If you want to see the beginning where we take the intake manifold off, you go to part one, and here's a brief view of the tools you'll need. Somewhat basic tools, a few things like a torque wrench and a flexing socket extension.

Up to this point, we've removed the intake manifold. There is a section between the heads where just some RTV gasket maker has used, so you want to be very careful to clean that out. Use a putty knife or razor blade and clean that up as best you can. Obviously, the cleaner you get it, the better it's going to seal. The same thing with your valve covers and your intake manifold, the more you clean them up, the better they'll seal and go back together. We're using a parts washer and degreaser here. You can actually use gasoline is a good solvent to do this kind of work with. Just do it in a way that's environmentally friendly.

Here's the new gasket set from 1A Auto. You can see it comes obviously with the lower intake gaskets, the valve cover gaskets, there's some different O-rings and other gaskets for the EGR valve, etc., as well as bolts. I'm going to stop it right here. You can see right where I'm pointing on the old gasket.

This is what happens on these vehicles, these 3.4-liters. You can see the gasket has failed around the water jacket there, and that's allowing coolant to get into the oil. You just want to line up those pins, and you can see some of the push rods will have to go over and some will have to go under. You will actually be able to see from the indents in the gasket what goes where. You just want to put those all in place.

You want to make sure that you get your push rods back underneath the rockers and in place. Then just tighten those rockers up with a 10mm socket. We'll just fast-forward here as he repeats process on the other side. Again, just make sure the push rods are in place and tighten them up. Tightening the rocker arms is crucial. The specification is 14 newton meters plus 30 degrees. 14 newton meters also equals 124 inch-pounds which is about 10 foot-pounds. That will tighten all 12 of them up that much, and then you tighten it another 30 degrees. Tighten them all with a torque wrench and another 30 degrees with your wrench.

Then you want to take some RTV, which is like a liquid gasket, and you just want to attach the two gaskets on either side of the intake manifold using this. Make sure that you do this on both sides. Once you've given that time to set, take your lower intake cover, and you want to have someone pull back the fuel injectors, and you just set that down into place. You want to go around and replace those 10mm bolts.

Now, you just want to torque those upper bolts to 13 newton meters and the lower bolts to 25 newton meters or 18 foot-pounds. It helps to have a swiveling extension so that you can get to this bolt right here and just torque that. Here's our now cleaned up valve cover, and you want to take this gasket that comes with the gasket set, and you just want to put this on your valve cover and just push it into place.

Now, you want to put the valve cover on and have someone hold it while you start the first bolt, and you just want to tighten up all those 8mm bolts. Now, on the valve cover and the back, make sure you have someone again to hold back the coil pack. Then you can put that valve cover on, start a bolt, and then tighten all four of the bolts up. Right here, on this pipe, there's an O-ring.

You want to remove that O-ring, and then just kind of scrape at this with a flat blade screwdriver to try to clean it up a little bit. In that gasket kit, you'll see there's a replacement O-ring for this. Once you get it cleaned up, you just want to put the new O-ring from 1A Auto into place. Once the O-ring is on, you can push it down into place, and you just want to replace the bolt.

Now, you just want to replace the bolt that holds this line in place. Take a wire brush, and you want to scrape up some of this debris that's on this pipe here. It's mainly just dried coolant. To scrape off all that, clean it up a little bit, take that tube and slide it back into place. Take a pair of pliers, push the two parts of the clamp together, and slide it forward to lock the tube in place. Now, you want to do the same thing here. Push this tube into place, slide the clamp forward, and you can tighten that with either a 7mm socket or a flat blade screwdriver. Again, install the upper hose and re-secure the clamp.

Now, you want to take these pulleys, and you just want to line that up. Once it's lined up, you just want to feed it down to the hole right there, as you can see, and you just want to turn that bolt to secure it into the hole there. You can do it by hand to start. Replace the 15mm bolt back here, and then there is a 15mm and a 16mm bolt that go on the side. You just want to put these back in place.

Now, you just want to put your power steering pulley back into place and you can replace the 13mm bolts to secure that. Now, you want to replace the wires on the back of the alternator and tighten up that 13mm bolt. Once that's tightened up, you want to just take that rubber boot and slide it back into place. You want to make sure that this bolt is already in place on the side before you put your alternator into place because the firewall will be in the way of getting the bolt in. Once you get the alternator in place, you can tighten up that bold and then replace the bolt in the front. You can now replace the bolt in that bracket in front of the power steering pulley.

You can now put your fuel injector leads into place. They are numbered. Just put them in order. It does have a number to match up above each fuel injector. Once you have the leads in place, you can line up those fuel injectors and push them down into place. You want to just replace these two bolts right here. You want to connect the lead right here in your alternator, and this lead down here.

You want to take your new gaskets from that gasket pack from 1A Auto and just put them here into place. There's one for each side. Down here, on this tube, you just want to scrape off the old O-ring and just clean that up a little bit, and then your gasket pack. There's a new O-ring, and you just want to put that into place and push that line into place. You just want to replace the nut down by that line you just plugged back in. There's actually another one right below it, and you want to replace that one as well.

Take this bracket that's in that gasket set from 1A Auto. Take your upper intake plenum, and you want to just line it up. Make sure this harness goes up through that hole on the back on your right there, and then just put that plenum into place. You want to just replace all the bolts that go along this. Make sure that if there's a bracket that goes in that spot, you put the bolt down through the bracket like right here. Just fast-forward. Tighten these bolts up evenly and then these bolts should be torqued to 18 foot-pounds.

In this bracket, you want to make sure that the harness goes underneath it. Then you want to just take this, plug it in right next to that harness, and then plug the other end up here, and then take this, plug that lead into it, and set that down into that bracket. You want to just tighten those bolts. You want to just replace your coil pack bolts to secure the coil pack back into place. Tighten those up real quick.

Then you want to replace the two bolts back down underneath the coil pack. You want to just reach down there using a flashlight to see where the holes are and put those back. Do it by hand first and then tighten them up. You want to just put that hose back into place, take the clamp using pliers, slide it forward, and it locks into place. You want to push this hose back into place. Same thing with this one.

On this vehicle, there's actually a plug. Here's the old manifold. You just see there's just a rubber plug there. Take it off for the old manifold and install it the same place for the new one. Maybe you want to bolt your throttle body back into place. Then you want to replace that nut on the bottom corner of the throttle body. Just replace the bolts up above the throttle body and tighten them.

Take this hose here, push it back, and then slide it down into place. Then you want to take your pair of pliers and push that clamp together and slide that forward. Then you want to take this hose, and you can see using a flat blade screwdriver, he's just positioning the hose on to that into place there and it just slides down into place. Again, take pliers, push the clamp forward, and replace that bolt, and tighten it.

Before putting your EGR on, put the new gasket from that gasket pack into place, and then line up your EGR. Put that into place and replace the bolt on either side. Once we tighten up the EGR, then we're going to cut off this part of the video. The next part of the video we're just going to finish up and get the thing running.

We hope this video helps you out. Brought to you by www.1AAuto.com, your source for quality replacement parts and the best service on the Internet. Please feel free to call us toll-free, 888-844-3393. We're the company that's here for you on the Internet and in person.

Tools needed for replacement:

    General Tools

  • Assistant
  • Drain Pan
  • Flashlight
  • Funnel
  • Putty Knife
  • Razor Blade / Gasket Scraper
  • Wire Brush

  • Materials, Fluids, and Supplies

  • RTV

  • Pliers, Cutters & misc Wrenches

  • Needle nose pliers

  • Ratchets & Related

  • 3/8 Inch Drive Ratchet
  • Socket Extensions
  • Swivel
  • Torque Wrench

  • Screwdrivers & Related

  • Flat Blade Screwdriver
  • Phillips Head Screwdriver

  • Sockets - Metric

  • 10mm Socket
  • 13mm Socket
  • 15mm Socket
  • 16mm Socket
  • 18mm Socket
  • 7mm Socket

1999 - 2003  Oldsmobile  Alero
1996 - 2003  Oldsmobile  Silhouette
2002 - 2003  Buick  Rendezvous
1999 - 2003  Pontiac  Grand Am
1999 - 2003  Pontiac  Montana
1996 - 1998  Pontiac  Trans Sport
2000 - 2003  Buick  Century
1996 - 2003  Chevrolet  Venture
2000 - 2003  Chevrolet  Monte Carlo
1996 - 1996  Chevrolet  Lumina APV
2001 - 2003  Chevrolet  Impala
2001 - 2003  Pontiac  Aztek
1999 - 1999  Chevrolet  Malibu
2000 - 2003  Chevrolet  Malibu

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