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How to Replace the Upper Intake Manifold on a 3800 Series II

The 3800 engine is a six-cylinder, 3.8-liter engine manufactured by General Motors. The Series II version of this engine was in production from 1996 to 2005, and appeared in various Buick cars during this period. The 3800 Series II engine contained many changes over the Series I engine, including a new intake manifold that improved the engines breathing. This intake manifold consisted of an upper and lower portion which are composed of cast iron.

Instructions

    1

    Remove the negative battery cable with a socket wrench to prevent the discharge of fuel. Place a pan under the radiator drain, and open the drain cock. Drain the coolant from the radiator, and store the coolant for later use. Replace the drain cock.

    2

    Remove the cap on the fuel tank to relieve the pressure in the tank. Wrap a shop rag around the pressure test port on the fuel rail to absorb spilled fuel. Connect a fuel pressure gauge to the test port, and place the bleed hose in a gasoline container. Open the valve on the fuel pressure gauge to relieve the pressure in the fuel system. Remove the shop rag and fuel pressure gauge from the fuel rail.

    3

    Disconnect the sight shield from the fuel injector with a socket wrench. Remove the air inlet duct and electrical wiring to the spark plugs on the right side of the engine. Disconnect the Manifold Absolute Pressure (MAP) sensor and the vacuum lines from the intake manifold. Detach the electrical connectors from the fuel injectors, and disconnect the fuel lines from the fuel regulator.

    4

    Detach the fuel rail and Exhaust Gas Recirculation (EGR) heat shield from the intake manifold with a socket wrench. Disconnect the bracket for the throttle cables and remove the throttle cables from the throttle body lever. Remove the upper intake manifold from the engine.

    5

    Install the new upper intake manifold to the engine, and tighten its mounting bolts to 88 inch-pounds with a torque wrench. Connect the throttle cable bracket and throttle cable to the throttle body lever with a socket wrench. Connect the EGR heat shield and fuel rail to the intake manifold. Tighten the mounting bolts for the fuel rail to 88 inch-pounds. with a torque wrench.

    6

    Connect the fuel lines to the fuel rail and fuel regulator. Attach the electrical connectors for the fuel injectors, and connect the vacuum lines to the intake manifold. Connect the electrical wiring for the MAP sensor and spark plugs. Connect the sight shield for the fuel injector and the air inlet duct with a socket wrench.

    7

    Fasten the fuel tank cap, and fill the radiator with coolant. Attach the negative battery cable with a socket wrench and start the engine. Correct any coolant or fuel leaks.

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