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Old 05-14-2005, 10:21 AM   #1
krushmoto
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Intake manifold Gasket replacement

Anyone have any tips on replacing the intake manifold gaskets? I've got a 2000 Malibu LS 3100 V6 w/ 105K mi. Thanks
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Old 06-08-2005, 09:35 PM   #2
goofy4467
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Re: Intake manifold Gasket replacement

it can be done with a hanes manual and some mechanical ability.
just leave the injectors in the intake until after it is removed. helps keep oout the dirt
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Old 06-09-2005, 07:59 AM   #3
steve_o
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I just completed this project on my 3.1L, and it can be done by a novice with a manual and a torque wrench. I used the Haynes manual.

Don't make the mistake I made by not paying attention to the fuel rail o-ring. It is I had read on other threads about it and do not remember seeing a fuel rail o-ring when I took it apart, so when I put it all together and started the car I had a real mess, that added hours before completion. It really came out like a fountain.

Ita was Sunday and I was able to buy a misc. (HELP) o-ring kit from Autozone that was rated for fuel, and it had one that fit. I also put one on the bottom of the fuel regulator connection, it looked like one could go there. I just didn't want the same problem.

While I was at it I replaced the spark plugs, thermostat, fuel filter, coolant, oil/filter, cam shaft position sensor (wires were frayed and previously caused a CEL).

Buy some extra silicon gasket sealant for where the intake maifold meets the valve covers, you'll see. Other than that it went pretty smooth, remember to bleed the air out of the coolant line. Any pay attention to how all the wires and hoses are routed makes the re-assemble easier.
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Old 06-09-2005, 09:23 PM   #4
mobil_12
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intake manifold

Looks like there is some good advice you got there.

Its always a good idea to replace your plugs, wires, thermostat, pcv, valve cover gaskets, and possibly serp belt cause they all have to come off the engine. No better time than the present. Also, a good idea is to replace your oil pump drive o ring ( at the rear of the engine block ).

Watching the fuel line o ring is gold... thats a mistake you make only once ! Some of the newer models, you can disconnect the fuel hoses by the master cylinder using quick connect tools. Then you can take the hoses out with the fuel rail and manifold without disturbing the o ring at the rail. Another is make darn sure that all your push rods go back in exactly the place they came from. The intake rods are a different length than the exhaust ones. Thats an expensive accident.

Use lots of sealer on the engine block to manifold areas and let it set up for at least a few hours before adding fluids.

When tightening the intake be sure to use the correct torque on the bolts and the correct torque sequence.

Remember to change the oil when you are done, if there is any coolant left in the engine, it goes directly to the oil pan when you take up the intake manifold.
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Old 01-22-2006, 10:26 AM   #5
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Re: Intake manifold Gasket replacement

I have the same leak issue and want to replace the manifold gasket. How in the heck do you drain the radiator? Thanks for the tips..........I've gotta get this stipid leak fixed.

Thanks;

Rick Williams
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Old 01-22-2006, 09:59 PM   #6
krushmoto
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Re: Intake manifold Gasket replacement

Well when you disconnect the hoses most of the coolant in the block will discharge. Just make sure you have something to catch it.
When you pull the manifold off whatever coolant is in the manifold will spill out into the block. MAKE sure before you reassemble the manifold take out the oil drain plug(keep it off until every drop of gunk drips out) & pour fresh oil all over the block and then after finishing the job replace the filter. Also make sure you do another oil change about 1K miles after.
That's what I did and my engine runs fine. I put on 150 mi/day and I average 75-80 mph. So in my opinion my engines fine. Let me know how you do with yours.
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Old 01-23-2006, 12:00 PM   #7
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Re: Intake manifold Gasket replacement

Quote:
Originally Posted by caymanis
I have the same leak issue and want to replace the manifold gasket. How in the heck do you drain the radiator? Thanks for the tips..........I've gotta get this stipid leak fixed.

Thanks;

Rick Williams
Removing the block drain helps too.
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Old 01-23-2006, 06:01 PM   #8
kev23
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Re: Intake manifold Gasket replacement

These are all very good hints, One article I found before I did mine was changes to the torque on the bolts, and make sure all the bolt threads are really clean before reassembly.

Adm Msg - New Intake Gasket for 3.1L LG8 and 3.4L LA1 Engines #vss20030024 - (03/04/2003)
Adm Msg -- New Intake Gasket for 3.1L LG8 and 3.4L LA1 Engines
1999-2003 Buick Century, Rendezvous; Chevrolet Impala, Monte Carlo, Venture; Oldsmobile Alero, Silhouette; Pontiac Aztek, Grand Am, Grand Prix and Montana
Service Manager, Parts Manager, Warranty Administrator
A new design intake gasket, P/N 89017279, has been released for service on the 3.1 and 3.4 engines and is currently available from GMSPO. The material used in the gasket has been changed in order to improve the sealing qualities of the gasket. The instruction sheet sent with the gaskets advises the technicians to replace the intake bolts with new ones that have a thread locker adhesive added. Currently the new bolts are unavailable from SPO. In the interim, the technicians are to clean the existing bolts and then apply a thread locking adhesive, P/N 12345382, and tighten to a new torque specification.

The new torque specification is a 2-step process;
tighten the vertical lower intake manifold bolts (the four middle ones) to 7 N•m (62 lb in).
Tighten the diagonal lower intake manifold bolts (two on each end) to 7 N•m (62 lb in).
Tighten the vertical lower intake manifold bolts (the four middle ones) to 13 N•m (115 lb in).
Tighten the diagonal lower intake manifold bolts (two on each end) to 25 N•m (18 lb ft).
The new torque specifications will be reflected in Thursday's down load of SI.
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Old 03-05-2006, 07:52 PM   #9
bcopeland
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Re: Intake manifold Gasket replacement

Any new data? I noticed a TSB on Alldata as of January 2006 that calls for a new upper intake manifold gasket kit (part # 89017554), a new upper intake manifold kit (part # 89017272), a new lower intake manifold gasket (part # 89017400) and a new lower intake manifold (part # 24508923). Any data on all of this?
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Old 03-07-2006, 02:19 PM   #10
bcopeland
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Re: Intake manifold Gasket replacement

By the way, I took it all apart and saw where on the original styled gasket, the end where the water circulates was busted and rotted. I went to Chevy dealership and they tried to sell me that old design for $70. Then I went to O'Reilly's and they sold me the "Problem-Solver" kit which was a much better design (steel with thick rubber where the water circulates) for the same price. I can't believe GM would still be selling that crap!
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Old 03-07-2006, 03:05 PM   #11
maxwedge
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Re: Intake manifold Gasket replacement

That must be the dealer, there has been an updated set out for quite a while, also recommended new stronger bolts and torque specs.
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Old 03-12-2006, 10:23 AM   #12
stratford_boy
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Re: Intake manifold Gasket replacement

A good way to make sure you get a minimum amout of coolant in the oil when doing intakes is to blow the intake and heads out with compressed air and a blow gun before lower int. removal...
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Old 05-23-2007, 08:41 PM   #13
webtyrant69
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Re: Intake manifold Gasket replacement

Quote:
Originally Posted by steve_o
I just completed this project on my 3.1L, and it can be done by a novice with a manual and a torque wrench. I used the Haynes manual.

Don't make the mistake I made by not paying attention to the fuel rail o-ring. It is I had read on other threads about it and do not remember seeing a fuel rail o-ring when I took it apart, so when I put it all together and started the car I had a real mess, that added hours before completion. It really came out like a fountain.

Ita was Sunday and I was able to buy a misc. (HELP) o-ring kit from Autozone that was rated for fuel, and it had one that fit. I also put one on the bottom of the fuel regulator connection, it looked like one could go there. I just didn't want the same problem.
I have the haynes manual as well for my 2002 venture, but didn't see anything about a fuel rail o-ring. I asked my neighborhood advance auto and they didn't know what I was talking about. The o-ring fits on the bottom hose, right? (view from in front of car)
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Old 05-23-2007, 10:41 PM   #14
errorcauser
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Re: Intake manifold Gasket replacement

Quote:
Originally Posted by webtyrant69
I have the haynes manual as well for my 2002 venture, but didn't see anything about a fuel rail o-ring. I asked my neighborhood advance auto and they didn't know what I was talking about. The o-ring fits on the bottom hose, right? (view from in front of car)

The o-ring goes right in here (circled in red)....

http://img372.imageshack.us/my.php?i...gine001bw5.jpg
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Old 06-02-2007, 07:36 AM   #15
webtyrant69
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Re: Intake manifold Gasket replacement

Would you happen to know the size of the ring? I bought a package of fuel o rings and do not know the size.
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