Intake Plenum replacement instructions needed

Hi,

When you do this, there is both an upper and lower manifold. All gaskets and O-rings will need to be replaced. I believe they sell a kit for this procedure at most parts stores which should include the necessary parts.

Here are the directions for removal and replacement. The pics below correlate with the directions. Note, the directions will start with the upper intake removal. This will need to be done prior to the lower.

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2005 Pontiac Grand Prix V6-3.8L VIN 2
10. Intake Manifold Removal - Upper
Vehicle Engine, Cooling and Exhaust Engine Service and Repair Overhaul Unit Repair 05 WP 3.8L VIN 2 Repair Instructions 10. Intake Manifold Removal - Upper
10. INTAKE MANIFOLD REMOVAL - UPPER
Intake Manifold Removal - Upper

pic 1

1. Remove the spark plug wires from spark plugs and retaining clips.
2. Remove the wiring harness from fuel rail.
3. Disconnect the ignition control module connector from the ignition control module assembly.
4. Remove the ignition control module assembly nuts.
5. Remove the ignition control module assembly.

Pic 2

6. Remove the fuel injector rail nuts.
7. Remove the fuel injector rail.

Pic 3

8. Remove the engine wiring harness heat shield bolt and nut.
9. Remove the engine wiring harness heat shield.

Pic 4

10. Remove the throttle body nuts and bolts.
11. Remove the throttle body.
12. Remove the throttle body seal.

Pic 5

13. Remove the upper intake manifold bolts and studs.
14. Remove the upper intake manifold.

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Install (upper)

2005 Pontiac Grand Prix V6-3.8L VIN 2
88. Intake Manifold Installation - Upper
Vehicle Engine, Cooling and Exhaust Engine Service and Repair Overhaul Unit Repair 05 WP 3.8L VIN 2 Repair Instructions 88. Intake Manifold Installation - Upper
88. INTAKE MANIFOLD INSTALLATION - UPPER
Intake Manifold Installation - Upper

pic 6

1. Install the upper intake manifold gasket.
2. Install the upper intake manifold.

Pic 7

3. Install the upper intake manifold bolts and studs.
Tighten the upper intake manifold bolts and studs in sequence to 10 Nm (89 inch lbs.).

Notice: Refer to Fastener Notice in Service Precautions.

Pic 8

4. Install the throttle body gasket.
5. Install the throttle body.
6. Install the throttle body nuts and bolts.
Tighten the throttle body nuts and bolts to 10 Nm (89 inch lbs.).

Pic 9

7. Install the engine wiring harness heat shield.
8. Install the engine wiring harness heat shield bolt and nut.
Tighten the engine wiring harness heat shield bolt and nut to 10 Nm (89 inch lbs.).

Pic 10

9. Install the fuel injector rail.
10. Install the fuel injector rail nuts.
Tighten the fuel injector rail nuts to 10 Nm (89 inch lbs.).

Pic 11

11. Install the ignition control module assembly.
12. Install the ignition control module assembly bracket nuts.
Tighten the ignition control module assembly bracket nuts to 50 Nm (37 ft. Lbs.).
13. Connect the ignition control module connector to the ignition control module assembly.
14. Install the wiring harness to the fuel rail.
15. Install the spark plug wires to the retaining clips and spark plugs.

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Lower Intake Removal

2005 Pontiac Grand Prix V6-3.8L VIN 2
12. Intake Manifold Removal - Lower
Vehicle Engine, Cooling and Exhaust Engine Service and Repair Overhaul Unit Repair 05 WP 3.8L VIN 2 Repair Instructions 12. Intake Manifold Removal - Lower
12. INTAKE MANIFOLD REMOVAL - LOWER
Intake Manifold Removal - Lower (L26)

pic 12

1. Remove the generator brace bracket bolts (569, 570).
2. Remove the generator brace bracket (571).

Pic 13

3. Remove the lower intake manifold bolts.

Important: Bolts which fasten the lower intake manifold to the cylinder head are accessible only after the upper intake is removed. The bolts are located in the right front and left rear corners of the lower intake manifold. Remove the upper intake manifold to service the lower intake.

4. Remove the lower intake manifold.
5. Remove the lower intake manifold gasket.

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Lower Install

2005 Pontiac Grand Prix V6-3.8L VIN 2
86. Intake Manifold Installation - Lower
Vehicle Engine, Cooling and Exhaust Engine Service and Repair Overhaul Unit Repair 05 WP 3.8L VIN 2 Repair Instructions 86. Intake Manifold Installation - Lower
86. INTAKE MANIFOLD INSTALLATION - LOWER
Intake Manifold Installation - Lower (L32)

pic 14

1. Clean the lower intake manifold sealing surface using GM P/N 12346139 (Canadian P/N 10953463) or equivalent prior to installing any seals or gaskets.
2. Install the lower intake manifold gasket.
3. Install the lower intake manifold.
4. Apply Threadlocker 272 GM P/N 12345493, (Canadian P/N 10953488) to the bolt threads.

Pic 15

5. Install the lower intake manifold bolts including the two hidden bolts.
Tighten the bolts in sequence to 15 Nm (11 ft. Lbs.).

Notice: Refer to Fastener Notice in Service Precautions.

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Let me know if this helps or if you have other questions

Take care and God Bless,

Joe