TSB 03-16-1 nightmare

[garync1]

Well did the old tsb today.. total price of parts 97.41.. Came off cheap until I broke the baffle and snap a brand new isolator bolt. did clean the egr ports though still got the broke bolt in there will have to start over.. hopefully they will let me buy one for 9.01 even though they come in a pack of 8. As for the upper intake manifold, found one online for 129.00 hopefully it comes with the baffel. if it were the lower it would be 309.00
I did put it back together with the broke bolt in there and a cracked baffel and it still ran, not very well though so it will be parked until new parts get in.. I just hope I can get 1 isolator bolt if not, one of the old ones is going back in.. The windshield coweling is a little more difficult to remove than I thought but will most likley remove on the next attempt if you take of the IAC to pull the upper intake off you are ok. still takes a little work...In the past it seemed alot easier to remove. WELL!! ONE THING I WILL NEVER DO. GO TO WORK FOR 12 HOURS AND COME HOME AND START FIXIN THE VAN.. Being tired got me in trouble..

[DRW1000]

Just curious.......Can you simply transfer the rubber from the new broken bolt to one of the old bolts? The rubber is the real difference.

Good luck the rest of the way

[garync1]

Originally Posted by DRW1000

Just curious.......Can you simply transfer the rubber from the new broken bolt to one of the old bolts? The rubber is the real difference.

Good luck the rest of the way

I have been trying but some how they are locked on there. Got to wait tell monday, dealers parts dept. closed,for the upper intake and baffle replacement.. It may have been good it broke though because the plastic seemed a little brittle.

[12Ounce]

Those bolts only require 8 ft-lbs of torque, IIRC. That ain't much torque!

[JoeJWill]

Originally Posted by garync1

Well did the old tsb today.. total price of parts 97.41.. Came off cheap until I broke the baffle and snap a brand new isolator bolt. did clean the egr ports though still got the broke bolt in there will have to start over.. hopefully they will let me buy one for 9.01 even though they come in a pack of 8. As for the upper intake manifold, found one online for 129.00 hopefully it comes with the baffel. if it were the lower it would be 309.00
I did put it back together with the broke bolt in there and a cracked baffel and it still ran, not very well though so it will be parked until new parts get in.. I just hope I can get 1 isolator bolt if not, one of the old ones is going back in.. The windshield coweling is a little more difficult to remove than I thought but will most likley remove on the next attempt if you take of the IAC to pull the upper intake off you are ok. still takes a little work...In the past it seemed alot easier to remove. WELL!! ONE THING I WILL NEVER DO. GO TO WORK FOR 12 HOURS AND COME HOME AND START FIXIN THE VAN.. Being tired got me in trouble.. :banghead:

I am experiencing the "baffle knock" on occasion and the 171/174 continuous code. The engine runs smooth other than the occassional knock and CEL on. I plan to begin the repair this week and need your advise on what not to do. I have read the bulletin on the TSB repair but would like to know how to prevent the isolator bolt break or baffle break, believe me if it can be broken I can do it....so all advise is valued greatly. JoeJWill

[garync1]

Just got done with the van I went ahead and got a new upper intake the baffle it is sealed to the top on the new one, the old one had 1 clip on each side.. I was unable to get the broke bolt out so I added a little more tension to the other bolts and put a little of blue rtv sealer around the one area just along the out side before it touches the oring port seal
If you do this I would take the front cowel off it is alot easier to work on.I got a inch lbs torque ratchet but it was useless because it felt to tight before it was going clicked so I snugged them down firm ,but not like before, although I did not put much pressure before when the bolt broke. So the pressure you put on the bolts are very important.. It runs better but will have to wait for cold morning start to get my final result.So to get rid of the plenum knock you most likely will have to re[lace plenum. 151.75 for the upper plenum. So I spent a little over 325.00 for the tsb not including materials...