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12-19-2004, 06:27 PM | #1 | |
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Replacing intake gasket...
anyone have any tips on replacing the intake gasket? i can see where coolant has leaked out from underneath and come out the sides of the motor beneath the intake gasket.. probably a bad definition but yall probably know what i mean.. i know its a common 3100 motor problem, so im sure theres a nice writeup on it somewhere... anyone?
thanks Nick |
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12-20-2004, 08:33 PM | #2 | |
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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). Condition 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. Cause Intake manifold may be leaking allowing coolant, oil or both to leak from the engine. Correction 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. Notice 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 Tighten the vertical lower intake manifold bolts (1) to 7N•m (62 lb in). Tighten the diagonal lower intake manifold bolts (2) to 7N•m(62 lb in). Tighten the vertical lower intake manifold bolts (1) to 13N•m(115 lb in). Tighten the diagonal lower intake manifold bolts (2) to 25N•m(18 lb ft). Parts Information Part Number Description Qty 89017279 Intake manifold Gasket 1 11588915 Intake manifold bolt - short 4 11588914 Intake manifold bolt - long 4 Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time J0259 Manifold or Gasket, Intake (Upper, Lower) - Replace Gasket Lower Use Published Labor Time |
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12-20-2004, 08:35 PM | #3 | |
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Re: Replacing intake gasket...
Well........I just did that yesterday. It was not alot of fun, but I have more time than money. The gaskets were $50.00 and you have to know which vin code you have, J or M. It took me about 9 hours plus the oil change and a coolant flush.
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10-31-2006, 01:18 PM | #4 | |
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Re: Replacing intake gasket...
Just did this repair. Special thanks to NickXXX for starting this thread and Bearcatdon for all that good info!!! 1st I'd heard for the warning about the tightening sequence.
Note: My torque wrench took a dump so I did the job without it. I paid alot of attention getting all the bolts torqued the same. Much to my suprise I've had no problems whatsoever. I guess I've had enough troubles in the past. Somebody likes me. If I had to do it over I would be smart and get a torque wrench though. p.s. don't lose the fuel inlet O-ring. Chevy dealer charged me 8 bucks for it. again thanks for the good info on the thread cheers |
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10-31-2006, 01:36 PM | #5 | ||
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Re: Replacing intake gasket...
Quote:
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11-08-2006, 02:26 PM | #6 | ||
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Re: Replacing intake gasket...
Quote:
After about two weeks I notice a small oil leak at the bottom of the lower intake. At that point I went straight out got a torque wrench and did the whole job over. I found I had under torqued most of the bolts. I got my time dowjn to under 6 hours, but I hope I never have to do it again. Next job that needs a torque wrench I will not fail to get one!!!! |
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11-09-2006, 01:24 AM | #7 | ||
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Re: Replacing intake gasket...
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11-27-2006, 07:01 AM | #8 | |
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Re: Replacing intake gasket...
I am to the point in this job where i need to remove the lower intake. I cannot free up the fuel rails in order to do this. I did not want to mess with the connections towards the master cylinder, or remove the fuel rails/injectors so I loosened the connections towards the right side of the rails (looking at the front of the car) but i can't get the rear fuel rail connections loose? Anyone else have this problem??
Also, I saw that many people ref the new GM gaskets, I was planning on using the Felpro ones available from AutoZone and the bolts that I removed, a good idea?? Thank you in advance. Desperate to fix this POS. Tom |
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11-27-2006, 08:00 PM | #9 | ||
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Re: Replacing intake gasket...
Quote:
I used Auto Zone parts and the original bolts which I cleaned, pipe doped and set with serviceable locktite. Knock on wood, that was 50,000 miles ago no leaks on mine or my buddy's. |
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11-27-2006, 08:24 PM | #10 | |
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Re: Replacing intake gasket...
Bear with me as I talk through your directions....If i am looking at the fuel rail as it is attached to the lower intake manifold I see 2 main sections, imagine x axis front and back. They are connected permanately by a section on the left hand side, y axis. On the right hand side there is a return line, fuel pressure regulator (connected to front rail) and in back the feed line with an odd bolt that screws into the fuel rail. If I loosen that bolt isn't there a way to remove that feed line?
If I picture the way you describe i follow that Feed line down along the block but eventually I hit a plastic sleeved section. Apparently I am lost. |
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11-27-2006, 09:58 PM | #11 | ||
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Re: Replacing intake gasket...
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11-28-2006, 05:29 AM | #12 | |
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Re: Replacing intake gasket...
I think I am on the same page with you now. The Return Line can be disconnected at the rail, I have been able to do that. As for the Feed Line what you are saying is that this must be disconnected at the firewall? I did not see that connection. What I saw on my car was a section about 10" from the firewall with some type of crazy connection that I do not know how to remove.
I noticed that part that attached the line to the block. I do not plan on removing the fuel rail or injectors at all. This job can be done without doing that at all. Thank you. |
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11-28-2006, 06:36 AM | #13 | |
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Re: Replacing intake gasket...
it looks like aldata tech info, gm decided to use plastic gasket frame with a inner rubber like seal, common fail on these engines. very very important push rods are different lengths!!!!! make 100% sure you dont mix intake and exhaust rods. i have been a tech for over 25 years this job is a little tricky even for veterans. good luck take your time and you can do it
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11-29-2006, 02:36 PM | #14 | ||
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Re: Replacing intake gasket...
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11-29-2006, 08:47 PM | #15 | |
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Re: Replacing intake gasket...
Alot of good advise in this thread. My engine seems to be leak free now.
Hope you( tczer34)found the fastener holding the fuel lines to the engine block ok. My big gripe was the damn inlet fuel line O-ring. It popped out Both times, and I had to go to the dealer to get another..8 bucks. Ouch |
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