Question 1

How to remove and reinstall the Intake Manifold in V6 engine on Pontiac Fiero?

Accepted Answer

To remove the components, first relieve the fuel system pressure, then disconnect the negative battery cable from the battery. Remove both rocker arm covers and drain the engine coolant. Disconnect and remove the intake hose between the throttle body and the elbow at the air cleaner canister, followed by removing the distributor cap and attached spark plug wires. Mark the position of the rotor and remove the distributor. Next, disconnect the shift linkage, throttle cable, downshift cable, and cruise control cable if applicable. Unbolt and remove the throttle body from the upper plenum, then disconnect the radiator hose and fill inlet. Disconnect the inlet and return heater hose and pipe from the throttle body, along with the wiring harness, labeling all wires for reinstallation. Disconnect the heater hoses and all vacuum hoses, labeling them for correct installation. Remove the brake booster pipe and bracket, the EGR pipe, and the upper manifold plenum along with the old gaskets. Disconnect the fuel line inlet and return fittings at the fuel block, then disconnect the wires from the fuel injectors. Remove the intermediate intake manifold and old gasket, noting that the intermediate intake manifold, fuel rail, and injectors can be removed as an assembly, followed by the lower intake manifold and old gaskets. For installation, clean the gasket surfaces on the cylinder head and intake manifolds, applying a smooth, continuous bead of sealant to the front and rear mating surfaces of the lower intake manifold and the top of the block, ensuring the surface is free of oil and dirt. Place the lower intake manifold and gasket in position, tightening all bolts in the proper sequence to the specified torque, then do the same for the intermediate intake manifold and gasket. Connect the wires to the injectors and the fuel line fittings to the fuel metering block, then place the upper manifold plenum and gaskets in position, tightening all bolts in the proper sequence to the specified torque. Bolt the throttle body to the upper plenum, install the EGR pipe, and the brake booster pipe and bracket. Reattach all vacuum hoses and heater hoses, reconnect the wiring harness, install the radiator fill inlet, and reattach the radiator hose. Reconnect the inlet and return heater hose and pipe to the throttle body, hook up the shift linkage, throttle cable, downshift cable, and cruise control cable, then install the distributor. Reattach the intake hose between the throttle body and the elbow at the air cleaner, tightening the hose clamps securely. Fill the engine with coolant, install both rocker arm covers, and finally, reattach the negative battery cable, checking the ignition timing and coolant level while looking for fluid leaks.

Question 2

How to properly remove and install an intake manifold in V6 engine on Pontiac Firebird?

Accepted Answer

If the vehicle has air-conditioning, examine the routing of the hoses and the compressor mounting carefully, as it may be possible to remove the intake manifold without disconnecting the system; if uncertain, consult a dealer or refrigeration specialist for system depressurization. Begin by disconnecting the cable from the negative battery terminal and draining the coolant from the radiator. For carbureted models, remove the air cleaner assembly, tagging each disconnected hose with numbered tape for easier reinstallation, then label and disconnect all electrical wires and vacuum hoses at the carburetor, followed by disconnecting the fuel line and plugging it to prevent contamination. Disconnect the throttle cable, spark plug wires, and wires at the coil, using numbered tape for labeling. Remove the distributor cap, distributor, power brake fitting, and mounting bracket, then move the power brake tube aside. Remove the solenoid/hose bracket, left and right rocker arm covers, upper radiator hose, heater hose, and vacuum lines from the TVS switch, along with the electrical connector from the coolant switch. Ensure all interfering wires, vacuum hoses, and coolant hoses are disconnected. If replacing the manifold, transfer external components from the old manifold, including the carburetor choke assembly, coolant switch, EGR valve, and emissions system TVS valve. Remove the manifold mounting bolts and separate the manifold from the engine without prying between mating surfaces; tap it gently with a hammer and wooden block if necessary. If installing a new manifold, transfer external components and clean the engine cavity, block, cylinder head, and gasket surfaces thoroughly, removing all gasket material and dirt. Apply a bead of R1V sealant to the engine block gasket surfaces, install new intake gaskets marked for the correct cylinder heads, and hold them in place with extended sealant. Carefully lower the intake manifold into position, ensuring the gaskets remain undisturbed, then install and tighten the mounting bolts according to the recommended sequence. Reinstall remaining components in reverse order, fill the radiator with coolant, start the engine, and check for leaks while adjusting ignition timing and idle speed as necessary. For fuel-injected models, remove the port fuel-injection components, disconnect spark plug wires and coil wires, and remove the distributor cap and distributor. Remove the air management hose, emission canister hoses, and rocker arm covers, then disconnect the upper radiator hose and heater hose, and remove coolant switches from the manifold. Loosen and remove the intake manifold bolts, separate the manifold from the engine without prying, and clean the mating surfaces thoroughly. If installing a new manifold, transfer external components and follow the remaining procedure as previously outlined.

Question 3

How can the procedure for removing and installing the intake manifold assembly be simplified in 2.2L four cylinder engine on Pontiac Grand Prix?

Accepted Answer

This procedure may be easier with the engine rotated forward. First, relieve the fuel pressure and then disconnect the negative battery cable from the battery, ensuring that the lockout feature of the Theftlock audio system is turned off before disconnecting the battery. Next, remove the upper intake manifold assembly. Raise the front of the vehicle and support it securely on jackstands, then drain the coolant. If necessary for clearance, remove the power steering pump (if equipped) and tie it aside in an upright position. Remove the heater hose and coolant line retaining nut near the bottom of the intake manifold, followed by the mounting nuts from the intake manifold. Separate the intake manifold and gasket from the engine, scraping all traces of gasket material off the intake manifold and head gasket mating surfaces while being careful not to scratch or gouge the delicate aluminum surfaces. Clean the surfaces with a rag soaked in lacquer thinner or acetone. Installation is the reverse of removal, ensuring to use a new gasket and tighten the nuts/bolts to the specified torque. Finally, add coolant, run the engine, and check for leaks and proper operation.

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