O-Ring Replacement Under Intake Manifold.

Greetings,

I have read numerous posts concerning this common problem with the 3.2L. I have experienced this as well with my 96 Rodeo with 200K + miles on it. Today I removed the Intake Manifold and verified that it was indeed leaking at the rear O-Ring. I have purchased the new O-Ring and Gasket set, and after cleaning everything up am poised to begin the re-installation of the Intake Manifold.

My question is in reference to the O-Ring itself. I haven't been able to find a thread that states whether or not the O-Ring should get a lubrication of some sort before re-installing. Should it go back on dry, or get some grease to help seal/seat the O-Ring?

Thanks for any help in tis matter. This is an awesome resource!!!!

I would use some kind of lube on it. Will make it slide in easier and reduce the chance of it tearing. I prefer silicone spark plug boot stuff, petrolium jelly works well too.

I used RTV to help slide it in and help with the seal. Still takes some force to get it in there. Are you doing the o-rings at the end of both pipes?

What fond memories!
http://img.photobucket.com/albums/v380/surferfletch/Rickspictures166.jpg

I have only removed the rear pipe/o-ring at this time. Everything else appeared ti be tught, and didn't want to mess with something not broken, however, I am sitting here thinking that maybe I should do both since it is a lot of trouble getting into this area. Wisdom would say---Might as well since I am already here!!!

So, consensus is--lube with something---RTV or Petroleum?

You also have access to a ton of small coolant hoses that are changed easily with the intake off. Bump for more suggestions.
http://www.automotiveforums.com/vbulletin/showthread.php?t=471459
Here's the thread from when I did it. The pics aren't current, but the Isuzu guru 2eyefishclaw was the one who suggested the RTV. Maybe you haven't found this thread...

UPDATE:

Finished job last night. Back up and running----here are a few tidbits to the next DIY'er......

I did replace the front (smaller o-ring) as well. The o-ring was a real pain to get back into the water sleeve, so I had to use sandpaper to custom fit the o-ring. After an hour or so of gently sanding, I was able to pull water pipe into place. The rear (larger pipe/o-ring) went back together with ease.

The gasket kit, which I got from Autozone (O'Reilly's didn't have one in stock), came with the wrong EGR gasket. I will be carrying it back today to get the right gasket. Without the proper gasket, it seems to have a vacuum and exhaust leak. My 96 Rodeo has a three bolt/triangular shaped egr gasket, so when get your gasket kit, ensure the proper EGR gasket is with it to keep from making a return trip!

I did use a silicone product on my o-rings and other hoses as I re-installed them. I didn't want to take a chance on some minor leak from back underneath intake manifold.

This job was really not very difficult to DIY. It is the first time I pulled this kind of intake system off, and even without the manual, it was pretty straight forward. On a scale of 1 to 10, with 10 being most difficult, I would give this a 3.

How many hoses/o-rings are there to replace under the plenum?

I'm waiting on the plenum gasket before I replace my intake gaskets but I wanna replace everything (within reason) that is located there. I have searched but cannot find the names/part numbers of these hoses/o-rings. I'm hoping to have them before starting in on the work as I would then be without a ride to go to the nearest parts store. Thanks

2001 Rodeo Sport
155k 4x2 3.2 v6

myisuzuparts.com