Intake manifold contains what I believe is a spring loaded valve meant to relieve excess pressure. (located right side end of intake). This valve opens constantly resulting in a vaccum leak and a rough running engine. Is the valve faulty (weak spring tension) or is it functioning as designed due to another problem? Replacing the valve means lifting the intake or removing the power steering pump in order to access. I've removed the Northstar intake cover as I believe it serves no function other than cosmetics but wonder if this is a factor

ok now before you start disconnect the negative battery cable then relieve the fuel pressure by opening the gas cap, then remove the valve cover, then the throttle body, remove the two clamps then disconnect the wire harness from the intake manifold, then the four injectors connectors from the injectors,then remove the engine wire protector from the right side of the intake manifold,remove the EGR valve and the EGR valve pipe,remove the top fitting on the fuel filter and remove the fuel line from the fuel filter,move the brake booster vacuum hose from the intake manifold disconnect the fuel line from the fuel rail,remove the fuel rail bolts, then remove the fuel injectors from the fuel rail,and when replacing the injectors always put new seals because the get hard and may not seal properly

All vehicles are equipped with a PCV (positive crankcase ventilation) valve that is located on top of a valve cover and connected to the intake manifold with a rubber hose. When the engine is running, there is some pressure from the combustion chambers that gets past the piston rings and into the crankcase. This is known as blowby. The PCV valve allows this pressure to be relieved and vented into the intake manifold. A thin film of oil will form in the intake manifold since the hot gases from the crankcase contain an oil vapor that cools and condenses once it is in the cooler air of the manifold.

The 3.1 engine does not have a belt,it is a chain motor.You do not need to remove timing chain to remove head.

The bolts should have thread lock on them when installing, and the torque is done in 2 steps. 33 ft lbs. and then 90 deg. after that on the second pass. 3.1L Engine CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. LEFT SIDE (FRONT)

1. Properly relieve the fuel system pressure.
2. Disconnect the negative battery cable.
3. Drain the cooling system into a suitable container.
4. Disconnect the top half of the air cleaner assembly, then remove the throttle body air inlet duct.
5. Remove the exhaust crossover pipe heat shield and crossover pipe.
6. Disconnect the spark plug wires from spark plugs and looms then route the wires out of the way.
7. Remove the rocker arm (valve) covers.
8. Remove upper intake plenum and lower intake manifold.
9. Remove the left side exhaust manifold.
10. Remove oil level indicator tube. NOTE: When removing the valve train components they must be kept in order for installation in the same locations they were removed from.
    
11. Remove rocker arms nut, rocker arms, balls and pushrods.
12. Unfasten the cylinder head bolts evenly, then remove the cylinder head from the engine compartment. Remove and discard the gasket. To install:
    
13. Clean all the gasket surfaces completely. Clean the threads on the cylinder head bolts and block threads.
14. Place the cylinder head gasket in position over the dowel pins on the cylinder block so the words THIS SIDE UP are showing.
15. Coat the bolt threads lightly with sealer, then install finger-tight.
16. Tighten the cylinder head bolts in sequence to 33 ft. lbs. (45 Nm). With all the bolts tightened make a second pass tightening all the bolts an additional 90°.
17. Install the pushrods, rocker arms, balls and rocker arm nuts in their proper locations. Tighten the rocker arm nuts to 18 ft. lbs. (25 Nm).
18. Install the lower intake manifold and upper intake plenum.
19. Install the rocker arm (valve) covers.
20. Install the oil level indicator tube. Insert the dipstick.
21. Connect the spark plug wires to spark plugs and looms.
22. Install the left side exhaust manifold.
23. Install the exhaust crossover pipe and heat shield.
24. Refill the cooling system.
25. Install the top half of the air cleaner assembly and the throttle body air inlet duct.
26. Connect negative battery cable.
27. Start vehicle and verify that there are no leaks. Fig. 20: Cylinder head mounting and bolt tightening sequence - 3.1L engine
    

RIGHT CYLINDER HEAD (REAR) CAUTION
Fuel Injection systems remain under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

1. Relieve the fuel system pressure.
2. Disconnect the negative battery cable.
3. Drain the cooling system.
4. Remove the top half of the air cleaner assembly and remove the throttle body air inlet duct.
5. Remove the exhaust crossover pipe heat shield and crossover pipe.
6. Raise and safely support the vehicle.
7. Detach the Oxygen (O2) sensor connector.
8. Disconnect the exhaust pipe from the exhaust manifold.
9. Remove the right side exhaust manifold.
10. Carefully lower the vehicle.
11. Disconnect the spark plug wires from spark plugs and wire looms and route the wires out of the way.
12. Remove the rocker arm (valve) covers.
13. Remove upper intake plenum and lower intake manifold. NOTE: When removing the valve train components they must be kept in order for installation in the same locations they were removed from.
    
14. Remove rocker arms nut, rocker arms, balls and pushrods.
15. Unfasten the cylinder head bolts evenly, then remove the cylinder head from the engine compartment. Remove and discard the gasket. To Install:
    
16. Clean all the gasket surfaces completely. Clean the threads on the cylinder head bolts and block threads.
17. Place the cylinder head gasket in position over the dowel pins on the cylinder block so the words THIS SIDE UP showing.
18. Coat the bolt threads lightly with sealer, then install finger-tight.
19. Tighten the cylinder head bolts in sequence to 33 ft. lbs. (45 Nm). With all the bolts tightened make a second pass tightening all the bolts an additional 90°.
20. Install the pushrods loosely retained with the rocker arm assemblies. Make sure all pushrods are in the correct locations. Coat the ends of the pushrods with prelube. The intake rods are marked yellow and are 5 3?4 inch long. The exhaust pushrods are marked green and 6 inches long. balls and rocker arm nuts. Tighten the rocker arm nuts to 18 ft. lbs. (25 Nm).
21. Install the lower intake manifold and upper intake plenum.
22. Install the rocker arm (valve) covers.
23. Connect the spark plug wires to spark plugs and wire looms.
24. Raise and safely support the vehicle.
25. Install the exhaust manifold.
26. Connect the exhaust pipe to the exhaust manifold.
27. Carefully lower the vehicle.
28. Connect the Oxygen (O2) sensor wiring.
29. Install the exhaust crossover pipe and heat shield.
30. Refill the cooling system.
31. Install the top half of the air cleaner assembly and the throttle body air inlet duct.
32. Connect negative battery cable.
33. Start vehicle and verify that there are no leaks.

Exactly what is the wrong? Need the part? Need to know torque adjust or porcedure to take off?

For 1994 Pontiac Grand Am 3.1L SFI OHV 6cyl check this procedure for Intake Manifold...
(see Figure 14)
The 3.1L engine is equipped with upper and lower intake manifolds. The upper intake manifold is also known as the intake manifold plenum.

CAUTION The fuel system is under pressure and must be properly relieved before disconnecting the fuel lines. Failure to properly relieve the fuel system pressure can lead to personal injury and component damage.

1. Relieve the fuel system pressure.
2. Disconnect the negative battery cable.
3. Remove top half of the air cleaner assembly and throttle body duct.
4. Drain and recycle the engine coolant.
5. Disconnect the EGR pipe from exhaust manifold.
6. Remove the serpentine belt.
7. Remove the brake vacuum pipe at the intake plenum.
8. Disconnect the control cables from the throttle body and intake plenum mounting bracket.
9. Remove the power steering lines at the alternator bracket.
10. Remove the alternator.
11. Label and disconnect the ignition wires from the spark plugs and wire retainers on the intake plenum.
    
12. Remove the ignition assembly and the EVAP canister purge solenoid together.

Fig. 14: View of the intake manifold and related components

1. Disconnect the upper engine wiring harness connectors at the following components:
   Throttle Position Sensor (TPS) Idle Air Control (IAC) Fuel Injectors Coolant temperature sensor Manifold Absolute Pressure (MAP) sensor Camshaft Position (CMP) sensor
2. Tag and disconnect the vacuum lines from the following components:
   Vacuum modulator Fuel pressure regulator PCV valve
3. Disconnect the MAP sensor from upper intake manifold.
4. Remove the upper intake plenum mounting bolts and lift off the plenum.
5. Disconnect the fuel lines from the fuel rail and bracket.
6. Install engine support fixture special tool J 28467-A or an equivalent.
7. Remove the right side engine mount.
8. Remove the power steering mounting bolts and support the pump out of the way without disconnecting the power steering lines.
9. Disconnect the coolant inlet pipe from the outlet housing.
10. Remove the coolant bypass hose from the water pump and the cylinder head.
11. Disconnect the upper radiator hose at thermostat housing.
12. Remove the thermostat housing.
13. Remove both rocker arm covers.
14. Remove the lower intake manifold bolts. Make sure the washers on the four center bolts are installed in their original locations.
    

When removing the valve train components they should be kept in order for installation the original locations.

1. Remove the rocker arm retaining nuts or bolts and extract the rocker arms and pushrods.
2. Remove the intake manifold from the engine. Remove and discard the gasket.
3. Using a suitable scraper, clean gasket material from all mating surfaces. Remove all excess RTV sealant from front and rear ridges of cylinder block
   

To install:

1. Place a 0.12 inch (3mm) bead of RTV, on each ridge, where the front and rear of the intake manifold contact the block.
2. Using a new gasket, place the intake manifold on the engine.
3. Install the pushrods in their original locations. Coat the pushrods with prelube.

The intake pushrods are marked yellow (5 3 /4 inch long) and the exhaust are green (6 inches long). Make sure the pushrods are properly seated in the valve lifters and rocker arms.

1. Position the rocker arms in there original locations and tighten to specifications. Refer to the procedure earlier in this section.
2. Install lower the intake manifold attaching bolts. Apply sealant 12345739 (or equivalent thread locking compound) to the threads of bolts. Tighten the vertical bolts first then the diagonal bolts to 115 inch lbs. (13 Nm).
3. Install the front rocker arm cover.
4. Install the thermostat housing.
5. Connect the upper radiator hose to the thermostat housing.
6. Fasten the coolant inlet pipe to thermostat housing.
7. Connect coolant bypass pipe at the water pump and cylinder head.
8. Install the power steering pump in the mounting bracket.
9. Loosely install the serpentine belt.
10. Connect the right side engine mount.
11. Remove the special engine support tool.
12. Fasten the fuel lines to fuel rail and bracket.
13. Install the upper intake manifold and tighten the mounting bolts to 18 ft. lbs. (25 Nm).
14. Install the MAP sensor.
15. Connect the upper engine wiring harness connectors to the related components removed earlier.
16. Connect the vacuum lines to the PCV, vacuum modulator and fuel pressure regulator.
17. Install the EVAP canister purge solenoid and ignition assembly.
18. Install the alternator assembly.
19. Connect the power steering line to the alternator bracket.
20. Install the serpentine belt.
21. Connect the spark plug wires to the spark plugs and intake plenum wire retainer.
22. Install the EGR pipe to the exhaust manifold.
23. Attach the control cables to the throttle body lever and upper intake plenum mounting bracket.
24. Install air intake assembly and top half of the air cleaner assembly.
25. Install the brake vacuum pipe.
26. Fill the cooling system.
27. Connect the negative battery cable, then start the vehicle and verify that there are no leaks.

For PARTS REPLACEMENT check in THIS LINK: carpartswholesale.com

Hope helps.

Bonneville, LeSabre, Park Avenue 2000-2005 Intake Manifold - Removal & Installation

3.8L Engine
VIN 1 Engine

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:
   Negative battery cable Supercharger Thermostat housing Exhaust Gas Recirculation (EGR) tube at the intake manifold Engine Control Temperature (ECT) sensor Intake manifold

To install:

1. Install or connect the following:
   Intake manifold with new gaskets. Torque the bolts, working from the center out, to 11 ft. lbs. (15 Nm). ECT sensor connector EGR tube to the intake manifold Thermostat housing Supercharger Negative battery cable
2. Refill and bleed the cooling system.
3. Run the engine and check for leaks and proper engine operation.

VIN K Engine

1. Before servicing the vehicle, refer to the Precautions section.
2. Disconnect the negative battery cable.
3. Drain the cooling system.
4. Relieve the fuel system pressure.
5. Remove or disconnect the following:
   Fuel injector sight shield Air inlet duct Spark plug wires from the right side Manifold Absolute Pressure (MAP) sensor Vacuum lines from the intake manifold Fuel lines Fuel injector electrical connectors Fuel regulator vacuum line Fuel rail from the intake manifold Exhaust Gas Recirculation (EGR) heat shield Throttle cable bracket from the cylinder head mounting bracket and the throttle body cables Throttle body support bracket Upper intake plenum and gasket Thermostat housing Electrical connector from the Engine Coolant Temperature (ECT) sensor Drive belt tensioner assembly EGR valve outlet pipe Lower intake manifold
   
   
   Fig. Exploded view of the intake manifold and related components-3.8L (VIN K) engine
   

To install:



Fig. Upper intake manifold torque sequence-3.8L (VIN K) engine



Fig. Lower intake manifold torque sequence-3.8L (VIN K) engine

1. Install or connect the following:
   Intake manifold using new manifold gaskets. Torque the bolts in sequence to 11 ft. lbs. (15 Nm); then, re-torque to 11 ft. lbs. (15 Nm). EGR valve outlet pipe Drive belt tensioner assembly. Torque the tensioner bolts to 37 ft. lbs. (50 Nm). Electrical connector to the ECT sensor Thermostat housing Upper intake plenum. Torque the intake plenum bolts to 88 inch. lbs. (10 Nm). Throttle body support bracket Throttle cable bracket to the cylinder head mounting bracket and the cables to the throttle body lever EGR heat shield Fuel rail. Torque the fuel rail bolts to 88 inch. lbs. (10 Nm). Fuel lines Fuel regulator vacuum line Fuel injector electrical connectors Vacuum lines to the intake manifold MAP sensor Spark plug wires Fuel injector sight shield and air inlet duct Negative battery cable
2. Refill and bleed the cooling system.
3. Run the engine and check for leaks and proper engine operation.

Hope this help (remember rated this).

This is for the 4.6L motor...I'll post for the 5.0L and 5.8L....you didn't post your engine size so please pick the applicable motor:

4.6L Engine
CAUTION Fuel injection systems remain under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

1. If equipped with air suspension, the air suspension switch, located on the right-hand side of the luggage compartment, must be turned to the OFF position before raising the vehicle.
   
2. Disconnect the negative battery cable.
   
3. Drain the engine cooling system.
   
4. Relieve the fuel system pressure as follows:
   
   1. Remove the fuel tank fill cap to relieve the pressure in the fuel tank.
      
   2. Remove the cap from the Schrader valve located on the fuel injection supply manifold.
      
   3. Attach Fuel Pressure Gauge T80L-9974-B or equivalent, to the Schrader valve and drain the fuel through the drain tube into a suitable container.
      
   4. After the fuel system pressure is relieved, remove the fuel pressure gauge and install the cap on the Schrader valve. Secure the fuel tank fill cap.
      
5. Disconnect the fuel supply and return lines.
   
6. Remove the windshield wiper governor (module).
   
7. Remove the engine air cleaner outlet tube.
   
8. Release the drive belt tensioner and remove the accessory drive belt.
   
9. Tag and disconnect the ignition wires from the spark plugs. Disconnect the ignition wire brackets from the cylinder head cover studs.
   
10. Disconnect the wiring from both ignition coils and the Camshaft Position (CMP) sensor. Tag and disconnect all ignition wires from both ignition coils. Remove 2 bolts retaining the ignition wire bracket to the ignition coil brackets and remove the ignition wire assembly.
    
11. Disconnect the alternator wiring harness from the junction block at the fender apron and alternator. Remove the bolts retaining the alternator brace to the intake manifold and the alternator to the cylinder block and remove the alternator.
    
12. Raise and safely support the vehicle.
    
13. Disconnect the oil pressure sensor and power steering control valve actuator wiring and position the wiring harness out of the way.
    
14. Disconnect the EGR valve to exhaust manifold tube from the right-hand exhaust manifold.
    
15. Lower the vehicle.
    
16. Remove and detach the engine/transmission harness connector from the retaining bracket on the power brake booster.
    
17. Detach the A/C compressor clutch, Crankshaft Position (CKP) sensor and the canister purge solenoid wiring connectors.
    
18. Remove the PCV valve from the cylinder head cover and disconnect the canister purge vent hose from the PCV valve.
    
19. Disconnect the accelerator and cruise control cables from the throttle body. Remove the accelerator cable bracket from the intake manifold and position out of the way.
    
20. Disconnect the vacuum hose from the throttle body adapter port.
    
21. Disconnect both Heated Oxygen Sensors (HO2S) and the heater water hose.
    
22. Remove 2 bolts retaining the thermostat housing to the intake manifold and position the upper hose and thermostat housing out of the way.
    

The 2 thermostat housing bolts are also used to retain the intake manifold.

1. Remove 9 bolts retaining the intake manifold to the cylinder heads and remove the intake manifold. Remove and discard the gaskets.
   
2. If replacing the intake manifold, swap over the necessary parts.
   

To install:

1. Clean all gasket mating surfaces.
   
2. Position new intake manifold gaskets on the cylinder heads. Make sure the alignment tabs on the gaskets are aligned with the holes in the cylinder heads.
   
3. Install the intake manifold and 9 retaining bolts. Hand tighten the right-rear bolt (viewed from the front of the engine) before final tightening, then torque the bolts, in sequence, to 15-22 ft. lbs. (20-30 Nm).
   
4. Inspect and if necessary, replace the O-ring seal on the thermostat housing. Position the housing and upper hose and install 2 retaining bolts. Torque to 15-22 ft. lbs. (20-30 Nm).
   
5. Reconnect the heater water hose.
   
6. Reconnect both HO2S wiring connectors.
   
7. Reconnect the vacuum hose to the throttle body adapter vacuum port.
   
8. Install the accelerator cable bracket on the intake manifold and connect the accelerator and cruise control cables to the throttle body.
   
9. Install the PCV valve in the cylinder head cover and connect the canister purge solenoid vent hose. Reconnect the A/C compressor clutch, CKP sensor and canister purge solenoid wiring connectors.
   
10. Reconnect the engine/transmission harness connector. Install the connector on the retaining bracket on the power brake booster.
    
11. Raise and safely support the vehicle.
    
12. Reconnect the EGR valve to exhaust manifold tube to the right-hand exhaust manifold. Torque the tube nut to 26-33 ft. lbs. (35-45 Nm).
    
13. Reconnect the power steering control valve actuator and the oil pressure sensor wiring connectors.
    
14. Lower the vehicle.
    
15. Position the alternator and install 2 retaining bolts. Torque to 15-22 ft. lbs. (20-30 Nm). Install 2 bolts retaining the alternator brace to the intake manifold and torque to 71-106 inch lbs. (8-12 Nm).
    
16. Reconnect the alternator wiring harness to the alternator, right-hand fender apron and junction block.
    
17. Position the ignition wire assembly on the engine and install 2 bolts retaining the ignition wire bracket to the ignition coil brackets. Torque the bolts to 71-106 inch lbs. (8-12 Nm).
    
18. Reconnect the ignition wires to the ignition coils in their proper positions. Reconnect the ignition wires to the spark plugs.
    
19. Reconnect the ignition wire brackets on the cylinder head cover studs. Reconnect the wiring connectors to both ignition coils and the CMP sensor.
    
20. Install the accessory drive belt.
    
21. Install the engine air cleaner outlet tube.
    
22. Install the windshield wiper governor.
    
23. Reconnect the fuel supply and return lines.
    
24. Fill and bleed the engine cooling system.
    
25. Reconnect the negative battery cable.
    
26. If equipped with air suspension, turn the air suspension switch to the ON position.
    
27. Start the engine and check for leaks.
    
28. Road test the vehicle and check for proper operation.
    

4.6L engine intake manifold torque sequence—1996-98 Models

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.

1. Properly relieve the fuel system pressure, as outlined in Section 5 of this manual.
   
2. Disconnect the negative battery cable.
   
3. Drain the cooling system into a suitable container.
   
4. Remove the fuel injector sight shield and air intake duct.
   
5. Tag and disconnect the spark plug wires on the right side of the engine and position aside.
   
6. Remove the manifold vacuum source.
   
7. Remove the fuel rail.
   
8. Remove the EGR heat shield.
   
9. Unfasten the cable bracket-to-cylinder head mounting bolt.
   
10. Disconnect the throttle cable.
    
11. Remove the throttle body support bracket.
    
12. 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.

1. Disconnect the upper radiator hose.
   
2. Remove the alternator, as outlined in Section 2 of this manual.
   
3. Remove the drive belt tensioner.
   
4. Remove the EGR valve outlet pipe.
   
5. 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:

1. 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.
   
1. Install the EGR valve outlet pipe.
   
2. Install the drive belt tensioner.
   
3. Install the alternator.
   
4. Connect the upper radiator hose.
   
5. Position the upper intake manifold on the lower manifold. Install the retaining bolts and tighten to 89 inch lbs. (10 Nm).
   
6. Install the throttle body support bracket, then connect the throttle cable.
   
7. Install the cable bracket-to-cylinder head mounting bolt.
   
8. Install the EGR heat shield.
   
9. Install the fuel rail.
   
10. Install the manifold vacuum source.
    
11. Connect the right side spark wires on the right side of the engine.
    
12. Install the fuel injector sight shield and air intake duct.
    
13. Fill the cooling system with the proper type and amount of fluid.
    
14. Connect the negative battery cable. Start the engine and check for leaks. Check the cooling system, and add as necessary.
    

Intake Manifold REMOVAL & INSTALLATION 1.9L SOHC Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Properly relieve the fuel system pressure.
3. Drain the coolant system.
4. Remove or disconnect the following:
   • Negative battery cable
   • Air cleaner fresh air hose
   • Positive Crankcase Ventilation (PCV) valve hose
   • Fuel line from the rail
   • Throttle cable from the throttle body
   • Throttle cable bracket nuts
   • Fuel injector electrical connectors
   • Throttle Position (TP) sensor electrical connectors
   • Idle Air Control (IAC) valve electrical connectors
   • Manifold Absolute Pressure (MAP) sensor electrical connectors
   • Exhaust Gas Recirculation (EGR) valve electrical connectors
   • Heater hose from the intake manifold outlet
5. Position the wiring harness over the brake master cylinder
6. Remove or disconnect the following:
   • Intake manifold support bracket bolt
   • Label the vacuum line for proper assembly
   • Drive belt
   • Power steering pump
   • Upper intake manifold bolts
   • Evaporative Emissions (EVAP) canister purge valve solenoid vacuum hose
   • Brake booster vacuum hose
   • Lower intake manifold bolts
   • Intake manifold
   To install:
   
7. Thoroughly clean all gasket mating surfaces. Be careful not to damage or score the aluminum surface. If replaced, use Loctite® 290, to seal the new PCV valve inlet tube into the manifold. NOTE: Refer to Section 1 of this manual for the intake manifold torque sequence illustration. The illustration is located after the Torque Specification Chart.
   
8. Install or connect the following:
   • New gasket and manifold. Torque the nuts in sequence to 22 ft. lbs. (30 Nm).
   • Power steering pump. Torque the fasteners to 27 ft. lbs. (38 Nm).
   • Drive belt.
   • Heater hose and install the manifold support bracket bolt. Tighten the bolt to 22 ft. lbs. (30 Nm).
   • Lubricate the male ends of the fuel lines with a few drops of clean engine oil, then connect the fuel supply and return lines.
   • Fuel line(s) in the retaining bracket. Torque the mounting screw to 36 inch lbs. (4 Nm).
   • Throttle cable to the throttle body and attach the accelerator cable bracket. Torque the bolts to 22 ft. lbs. (30 Nm).
   • Reposition the wiring harness and connect the wiring and vacuum hoses to their original locations. The harness leads to the TP sensor and EGR solenoid must be routed between the intake manifold runners.
   • Negative battery cable
9. Fill the coolant system.
10. Prime the fuel system by cycling the ignition ON for 5 seconds and OFF for 10 seconds a few times without cranking the engine.
11. Start the engine, check for leaks, and repair if necessary.

How's your coolant level? The intake manifolds on the 3.8L engines are prone to breakage at various locations causing coolant leaks into the crankcase and vacuum leaks on intake ports.Removal of the upper intake manifold will be necessary for inspection. Also, check for vacuum leaks at various locations on the outside of the intake manifold using WD-40 or brakeclean/carburetor cleaner sprayed hoses, non-electrical components, at the base of the manifold etc. As for a faulty injector, not likely but if you suspect one you can always swap the suspect injector with another on the engine and see if the misfire follows the injector. Just be sure to relieve the fuel pressure before servicing. Hope this helps.