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Old 12-20-2004, 09:33 PM   #2
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Join Date: Mar 2004
Location: springfield, Illinois
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Re: Replacing intake gasket...

1) Take your time especially if this is the first time. A manual is also useful
2) Label wires as you remove them
3) Raise the engine and remove the RH motor mount to move the power steering pump out of the way.
4) When disconnecting the fuel line from the rail be very careful not to lose the green o-ring
5) Pull the intake manifold followed by removing the pushrods and rotating rocker arms
6) Stand the pushrods in a box the same way they came out. I use a screwdriver and punch 12 holes in an old box. Make sure you write on the box cyl. 1, front of car etc. It is extremely important that you do not mix them up.
7) Clean all gasket surfaces properly.
8) Use pipe dope on your intake bolts. I also added serviceable loctite.
9) Torque all bolts to the new GM specs. See below
10) Oil the fuel injector o-rings when reinstalling and make sure they are properly seated.
11) Change your plugs, wires, belt and thermostat now that you have full access to all these things.

I pulled this document from the forum a while back..not sure who originally posted it.
Document ID# 1396678
2003 Chevrolet Malibu


Engine Oil or Coolant Leak (Install New Intake Manifold Gasket) #03-06-01-010B - (10/24/2003)
Engine Oil or Coolant Leak (Install New Intake Manifold Gasket)
2000-2003 Buick Century

2002-2003 Buick Rendezvous

1996 Chevrolet Lumina APV

1997-2003 Chevrolet Venture

1999-2001 Chevrolet Lumina

1999-2003 Chevrolet Malibu, Monte Carlo

2000-2003 Chevrolet Impala

1996-2003 Oldsmobile Silhouette

1999 Oldsmobile Cutlass

1999-2003 Oldsmobile Alero

1996-1999 Pontiac Trans Sport

1999-2003 Pontiac Grand Am, Montana

2000-2003 Pontiac Grand Prix

2001-2003 Pontiac Aztek

with 3.1L or 3.4L V-6 Engine (VINs J, E - RPOs LG8, LA1)

This bulletin is being revised to change the model Information. Please discard Corporate Bulletin Number 03-06-01-010A (Section 06 - Engine).

Some owners may comment on an apparent oil or coolant leak. Additionally, the comments may range from spots on the driveway to having to add fluids.

Intake manifold may be leaking allowing coolant, oil or both to leak from the engine.

Install a new design intake manifold gasket. The material used in the gasket has been changed in order to improve the sealing qualities of the gasket. When replacing the gasket, the intake manifold bolts must also be replaced and torqued to a revised specification. The new bolts will come with a pre-applied threadlocker on them.

An oil leak may result if the vertical bolts are not tightened before the diagonal bolts.

Diagonal bolts may require a crows foot to tighten.

Tighten the vertical lower intake manifold bolts (1) to 7Nm (62 lb in).
Tighten the diagonal lower intake manifold bolts (2) to 7Nm(62 lb in).
Tighten the vertical lower intake manifold bolts (1) to 13Nm(115 lb in).
Tighten the diagonal lower intake manifold bolts (2) to 25Nm(18 lb ft).
Parts Information
Part Number

Intake manifold Gasket

Intake manifold bolt - short

Intake manifold bolt - long

Parts are currently available from GMSPO.

Warranty Information
For vehicles repaired under warranty, use:

Labor Operation
Labor Time

Manifold or Gasket, Intake (Upper, Lower) - Replace Gasket Lower
Use Published Labor Time
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