Coolant leak on side of lower intake

Ok 2 yrs ago, I replaced upper and lower intake gaskets, as well as replaced upper intake plenum. The intake kit came with a number of O rings and a gasket for what it called "Water manifold." I assume it was a small piece on the right side of the lower intake. Didnt have problem with it so I never bothered with it. 2 years later and now its leaking coolant there. I still have the gasket for it but my problem lies here: in the Chilton's repair manual, it doesnt discuss it but only mentions it in the troubleshooting section. Why that is a problem with is because I need to know the torque to apply to the bolts and also if I need to use sealant. I've called several GM dealerships and I mostly get is, "Oh, been a long time since we dealt with that engine. Um not sure, trying calling another GM dealership." Or they give a guess like try 10 ft pounds or 19, etc. I'm not looking for a guess, I need a direct answer and I want to do the job right.

P.S. Did I mention that I love my Intrigue? I do! :biggrin:

What year and engine? I'll see what GM service information lists as a torque spec. It is usually a good idea to put a bit of pipe sealant or medium strength loctite on bolt threads near coolant passages in case of any porosity.

What year and engine? I'll see what GM service information lists as a torque spec. It is usually a good idea to put a bit of pipe sealant or medium strength loctite on bolt threads near coolant passages in case of any porosity.


1999 with a 3800 series 2.

You are talking about the coolant blockoff plate circled in red correct?
http://i36.photobucket.com/albums/e50/twabelljr/Intake.gif
I can find illustrations of it, but nothing names it or gives a torque spec. I looked in other manuals for cars with a VIN K 3.8 and nothing. I don't know what dealer would not see these engines anymore. We see them all the time. All I can suggest that if the bolts are 6mm x 1.0 thread, apply a bit of loctite or pipe sealer and torque them to 89lbin. and see how it feels with a ratchet. Most 6mm x 1.0's are 89lbin. and I believe these are 6mm x 1.0's. If they are 8mm bolts hand tighten them to what feels good, maybe 15lbft.? I'm speechless. I like to put a number on things and follow torque specs but this is a strange case. Use your sense of feel and best judgement. Don't crack the gasket and tighten them evenly.

You are talking about the coolant blockoff plate circled in red correct?
http://i36.photobucket.com/albums/e50/twabelljr/Intake.gif
I can find illustrations of it, but nothing names it or gives a torque spec. I looked in other manuals for cars with a VIN K 3.8 and nothing. I don't know what dealer would not see these engines anymore. We see them all the time. All I can suggest that if the bolts are 6mm x 1.0 thread, apply a bit of loctite or pipe sealer and torque them to 89lbin. and see how it feels with a ratchet. Most 6mm x 1.0's are 89lbin. and I believe these are 6mm x 1.0's. If they are 8mm bolts hand tighten them to what feels good, maybe 15lbft.? I'm speechless. I like to put a number on things and follow torque specs but this is a strange case. Use your sense of feel and best judgement. Don't crack the gasket and tighten them evenly.


Yes, thats the part in question. I was hoping you would be able to find torque specs for it, I'll give it a shot. Though if it turns out that its still leaking afterwards, it'll be a pretty expensive replacement as I would have to buy a whole intake kit just to get a replacement gasket.

RockAuto lists a "Coolant Water Bypass" gasket for that engine. It looks like it should be what youre looking for, a smallish square-shaped gasket. Its under the "cooling system" section. Costs 4.50 plus shipping.

You might also be able to get the gasket locally without having to buy the whole kit over again.