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intake manifold gasket - 97 Pontiac Grand Am

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waterdude
Novice

Dec 10, 2011, 3:08 PM

Post #1 of 11 (3950 views)
intake manifold gasket - 97 Pontiac Grand Am Sign In
just getting started & need to relieve the fuel pressure. Can anyone tell me where theres a valve to relieve the fuel pressure.


Discretesignals
Ultimate Carjunky / Moderator
Discretesignals profile image

Dec 10, 2011, 3:52 PM

Post #2 of 11 (3922 views)
Re: intake manifold gasket - 97 Pontiac Grand Am Sign In
If it is an intake gasket, it is probably going to be the 3.1L. The pressure test port is on the rear rail by the alternator and power steering pump.

If it is the 2.4L, there is no test port and you'll have to wrap a rag around the fuel supply connector while disconnecting it.

If either engine runs, you can relieve fuel pressure by disconnecting the fuel sender connector down by the gas tank while the engine is idling. The engine will quit when it runs out of gas.

Unless your going to take the injectors out of the rail, you don't need to disconnect the rail on the 3.1L. Once you get the rail unbolted and the fuel supply line unbolted from the bracket on the side of the engine, you can lift and move the rail out of the way without disconnecting it.





Since we volunteer our time and knowledge, we ask for you to please follow up when a problem is resolved.


Sidom
Veteran / Moderator
Sidom profile image

Dec 10, 2011, 5:00 PM

Post #3 of 11 (3909 views)
Re: intake manifold gasket - 97 Pontiac Grand Am Sign In
2 suggestions off the top of my head.....Don't mix up the push rods (yes it is possible) and if you take the rockers off, be sure to torque them back to specs, overtorquing can ruin the threads and cause big problems down the road...


Discretesignals
Ultimate Carjunky / Moderator
Discretesignals profile image

Dec 11, 2011, 8:16 AM

Post #4 of 11 (3886 views)
Re: intake manifold gasket - 97 Pontiac Grand Am Sign In
Exactly Sid, don't get the exhaust and intake pushrods switched. The exhaust push rods are longer than the intake push rods. You get them switched and you'll be putting a camshaft in it.

Another suggestion is to use Fel-pro permadry intake gasket kit. They have a steel carrier instead of plastic. Haven't had one come back as of yet using that design.




Lisle has come up with a tool (48500), so you don't have to unbolt the rocker arms.







Since we volunteer our time and knowledge, we ask for you to please follow up when a problem is resolved.

(This post was edited by Discretesignals on Dec 11, 2011, 8:21 AM)


waterdude
Novice

Dec 11, 2011, 3:28 PM

Post #5 of 11 (3864 views)
Re: intake manifold gasket - 97 Pontiac Grand Am Sign In
Slow and go for me. Theres a pipe that threads into the manifold by the thermostat housing that goes to the back the car. It looks like it should come off but I really don't want to screw anything up. Should I un-screw it from the housing or take it off further down where the hose clamp is? Thanks for your help!!!


Hammer Time
Ultimate Carjunky / Moderator
Hammer Time profile image

Dec 11, 2011, 3:36 PM

Post #6 of 11 (3858 views)
Re: intake manifold gasket - 97 Pontiac Grand Am Sign In
TOOL REQUIRED
  • J 28467-360 Engine Support Fixture

REMOVAL
  1. Disconnect the negative battery cable.
  2. Depressurize the fuel system. See Powertrain Management.
  3. Remove the top half of the air cleaner assembly.
  4. Drain and recover the cooling system. See Cooling System.





  1. Remove the EGR pipe from the exhaust manifold.
  2. Remove the drive belt.
  3. Remove the brake vacuum pipe at the plenum.
  4. Remove the power steering lines at the generator bracket.
  5. Remove the generator. See Starting and Charging.





  1. Remove the secondary ignition wires from the spark plugs.
  2. Remove the secondary ignition wires from the harness at the plenum.
  3. Remove the following components at the same time:
    • Electronic ignition coil and module assembly
    • EVAP canister purge solenoid
  1. Remove the following upper engine wiring connectors:
    • Throttle Position (TP) sensor
    • IAC sensor
    • Injector harness
    • Engine Coolant Temperature (ECT) sensor
    • MAP sensor
    • Camshaft Position (CMP) sensor
  1. Remove the following vacuum lines:
    • Vacuum Modulator
    • Fuel Pressure Regulator
    • PCV
  1. Remove the, MAP sensor from the upper intake manifold.





  1. Remove the upper intake manifold bolts.
  2. Remove the upper intake manifold.





  1. Remove the fuel lines at the fuel rail and the bracket.
  2. Install the Engine Support Fixture.
  3. Remove the engine mount assembly.
  4. Remove the power steering mounting bolts. Support the pump aside. See Steering and Suspension.
  5. Remove the coolant inlet pipe from the coolant outlet housing.
  6. Remove the coolant by-pass at the coolant pump and the cylinder head.
  7. Remove the radiator hose at the coolant outlet housing.
  8. Remove the coolant outlet housing.
  9. Remove both of the valve rocker covers.

NOTE: Retain the washers in the same orientation on the center bolts.




  1. Remove the lower intake manifold bolts.
  2. Remove the lower intake manifold.





  1. Loosen the rocker arms.

CAUTION: Keep the pushrods in order. The pushrods must be installed in the original position.




  1. Remove the pushrods.
  2. Remove the intake gasket.
  3. Inspect the flatness of the inlet flanges.
  4. Clean the following items:
    • Gasket material from the mating surfaces
    • Excess RTV sealant from the front and the rear ridges of the cylinder
    • Block
    • Sealing surfaces with degreaser

INSTALLATION
  1. Place a 2-3 mm bead of GM RTV sealer P/N 1052917, or equivalent on each ridge where the front and the rear of the intake manifold contact the block.
  2. Install the intake manifol gasket.
  3. Install the pushrods.
    1. Install the pushrods in their original location.
    2. Coat the ends of the pushrods with prelube GM P/N 1052356, or equivalent.
    3. Intake pushrods are marked yellow and are 5 3/4 inch long.
    4. Exhaust pushrods are marked green and are 6 in long.
    5. Ensure that the pushrods seat in the lifter.
  1. Install the rocker arm bolts. Tighten the bolts to 14 Nm (124 lb in) + 30° .
  2. Install the lower intake manifold.
  3. Install the lower intake manifold bolts. Apply sealant GM P/N 12345739 to the threads of the bolts.

Notice: The OEM service manual does not provide a torque sequence for the upper or lower intake manifolds.

  1. First, tighten the vertical bolts to 13 Nm (115 lb in) .
  2. Then, tighten the diagonal bolts to 13 Nm (115 lb in) .
    1. Install the front valve rocker cover.
    2. Install the coolant outlet housing.
    3. Install the radiator hose to the thermostat housing.
    4. Install the coolant inlet pipe to the thermostat housing.
    5. Install the coolant by-pass pipe at the coolant pump and the cylinder head.
    6. Install the power steering pump. See Steering and Suspension.
    7. Loosely, install the drive belt.
    8. Install the engine mount assembly.
    9. Remove the engine support fixture.
    10. Install the fuel lines to the fuel rail and the bracket.
    11. Install the upper intake manifold.
    12. Install the upper intake manifold bolts. Tighten the bolts to 25 Nm (18 lb ft) .
    13. Install the MAP sensor.
    14. Connect the following vacuum lines:
    • Vacuum Modulator
    • Fuel Pressure Regulator
    • PCV
    1. Install the following upper engine wiring connectors:
    • TP sensor
    • IAC
    • Injector harness
    • ECT sensor
    • MAP sensor
    • CMP sensor
    1. Install the following components:
    • EVAP canister purge solenoid
    • Electronic ignition coil and module assembly
    1. Install the generator. See Starting and Charging.
    2. Install the power steering line at the generator bracket.
    3. Install the drive belt.
    4. Install the secondary ignition wires to the spark plugs.
    5. Install the secondary ignition wires to the harness at the plenum.
    6. Install the EGR pipe to the exhaust manifold.
    7. Install the following items to the throttle body:
    • Throttle body cable
    • Cruise control cable
    1. Install the top half of the air cleaner assembly.
    2. Install the brake vacuum pipe.
    3. Install the cables to the throttle body.
    4. Fill the cooling system. See Cooling System.
    5. Connect the negative battery cable.
    6. Inspect for proper fluid levels.
    7. Check for leaks.




~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

We offer help in answering questions, clarifying things or giving advice but we are not a substitute for an on-site inspection by a professional.



waterdude
Novice

Dec 11, 2011, 3:41 PM

Post #7 of 11 (3852 views)
Re: intake manifold gasket - 97 Pontiac Grand Am Sign In
Thanks Hammer!


Discretesignals
Ultimate Carjunky / Moderator
Discretesignals profile image

Dec 11, 2011, 4:56 PM

Post #8 of 11 (3839 views)
Re: intake manifold gasket - 97 Pontiac Grand Am Sign In
The coupler where the metal pipe fits into has two plastic ears that you squeeze together to unlock the pipe from the coupler.

Replace the coupler once you have the intake off. They stock ones are cheap pot metal and you'll have a leak later on. If it snaps off trying to unscrew it from the manifold, you can take a hacksaw blade and cut it in three places just above the threads. Then use a small chisel to knock the pieces out.







Since we volunteer our time and knowledge, we ask for you to please follow up when a problem is resolved.

(This post was edited by Discretesignals on Dec 11, 2011, 5:05 PM)


Sidom
Veteran / Moderator
Sidom profile image

Dec 11, 2011, 6:36 PM

Post #9 of 11 (3828 views)
Re: intake manifold gasket - 97 Pontiac Grand Am Sign In
In Reply To
Lisle has come up with a tool (48500), so you don't have to unbolt the rocker arms.

My tool has a different name & #.....It's a Snap On 12mm crowsfoot...........Sly


Discretesignals
Ultimate Carjunky / Moderator
Discretesignals profile image

Dec 11, 2011, 8:11 PM

Post #10 of 11 (3814 views)
Re: intake manifold gasket - 97 Pontiac Grand Am Sign In
That's a good idea, Sid. I'll have to try that. I usually use a crescent wrench.





Since we volunteer our time and knowledge, we ask for you to please follow up when a problem is resolved.


Sidom
Veteran / Moderator
Sidom profile image

Dec 11, 2011, 8:20 PM

Post #11 of 11 (3807 views)
Re: intake manifold gasket - 97 Pontiac Grand Am Sign In
It gets into tight areas & you can get the pushrods out while the v/c covers are still on....

On some the 12 is just a bit tight so a 13 works, just fits a bit loose...... Personally I take all the ones that aren't up on the lobes and then roll the motor....but I've seen guys do it without doing that, personally I thing that just puts too much stress on the rockers and bolts but so far haven't seen any problems (yet) with those jobs.....

I didn't even know they make a tool for that now.....


(This post was edited by Sidom on Dec 11, 2011, 8:20 PM)





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