Intake manifold gasket replacement

[pvisser]

I have a 1999 Pontiac Montana with just over 200000KM's on it. Have just come to find that its intake gasket is leaking out. This is my third time exposed to this situation, but my first time not covered by warranty. I am planning on replacing by myself, just had one question. Does the manifold need to be machined? or is this simply a remove and replace procedure?

Any hints would be great. I also plan to replace plugs and wire while I am in there...

Thanks

[Zogboy]

Originally Posted by pvisser

I have a 1999 Pontiac Montana with just over 200000KM's on it. Have just come to find that its intake gasket is leaking out. This is my third time exposed to this situation, but my first time not covered by warranty. I am planning on replacing by myself, just had one question. Does the manifold need to be machined? or is this simply a remove and replace procedure?

Any hints would be great. I also plan to replace plugs and wire while I am in there...

Thanks

I need to replace a gasket as well and could use a few tips too.

Any tips to doing this would be a great help.

[brian 1]

just clean intake surface real good,you do not have to machine anything.try to use oem parts.they come in a full kit with the new bolts and gaskets.take all guess work out for replacement.also dont mix up push rods,they are different lengths.take your time doing this job and it will come out wright.

[hufhouse]

Go to the Chevy Venture category on this discussion board. There, you will find a sticky topic with more reading than you can do in a couple of hours all about the intake manifold gasket replacement.

Things to watch out for:

- There are new torque specs for the bolts on the intake manifold. Use new bolts and torque as directed.

- The gasket was redesigned. Make sure you get the new design.

- While you are at it, this is a good time to replace the plugs. You'll never have it easier.

- I replaced the plugs, wires, belts and hoses, as well as flushing and filling the radiator and changing the transmission fluid. Oh, and I also replaced the o-rings on the fuel injectors, and an o-ring on the fuel rail. And the fuel filter. The whole ordeal took me about eighteen hours. I'm not proud of that.

- There is nothing particularly hard or highly technical about this repair. It just takes a long time and a lot of patience. I suggest that you label every vacuum hose and electrical connector. I used masking tape and started with "A" and worked my way through the alphabet, marking both sides of each connection. It probably wouldn't hurt to take a few digital photos before you start, just to make sure everything gets back together the same way.

- I felt like a combination of the Haynes Manual and the info from the Chevy Venture board was enough to make me feel like I was ready to tackle this.

['97ventureowner]

http://www.automotiveforums.com/vbul...d.php?t=321467

[rkvons]

Just did mine recently. Went without a hitch. Check this out:
http://www.d-tips.com/General/Articl...sket/art10.art

-Rick

[1Bradymichael]

Originally Posted by hufhouse

Go to the Chevy Venture category on this discussion board. There, you will find a sticky topic with more reading than you can do in a couple of hours all about the intake manifold gasket replacement.

Things to watch out for:

- There are new torque specs for the bolts on the intake manifold. Use new bolts and torque as directed.

- The gasket was redesigned. Make sure you get the new design.

- While you are at it, this is a good time to replace the plugs. You'll never have it easier.

- I replaced the plugs, wires, belts and hoses, as well as flushing and filling the radiator and changing the transmission fluid. Oh, and I also replaced the o-rings on the fuel injectors, and an o-ring on the fuel rail. And the fuel filter. The whole ordeal took me about eighteen hours. I'm not proud of that.

- There is nothing particularly hard or highly technical about this repair. It just takes a long time and a lot of patience. I suggest that you label every vacuum hose and electrical connector. I used masking tape and started with "A" and worked my way through the alphabet, marking both sides of each connection. It probably wouldn't hurt to take a few digital photos before you start, just to make sure everything gets back together the same way.

- I felt like a combination of the Haynes Manual and the info from the Chevy Venture board was enough to make me feel like I was ready to tackle this.

One thing the engineers did right was making all the electrical connections so they would only fit in one particular spot. I should know, I have had mine apart 3x now, and am not proud of that.

[hufhouse]

I noticed that as I was putting everything back together. However, labeling everything still helped me locate stuff more easily. Plus, there are still those pesky vacuum connections.

But, you're right. You really can't mess up the electrical connections.

[mstbone67a]

Is there a way to sticky this thread that has the link to
http://www.d-tips.com/General/Articl...sket/art10.art

[wafrederick]

It is horrible and I did one so far.Air tools are a must for this job.Fel Pro does has fixed the problem,they have metal ones which are better than the plastic one.The metal ones are more money and this is another option on the gaskets.I have some advice,do not torque the intake bolts.The problem with torqueing them down is that most over torque them and the job has to be done over.I know a Carquest parts store that has heard of this happening.Run them down with a 3/8" impact and hand tighten with a hand ratchet instead.I believe most torque specs are made for breaking bolts.One of the worst parts are those plastic water fittings which I call junk.I hate them and that is one of GM's mistakes.Her is another tip,put the alternator in place before putting on the upper plenuim.It is a pain in the but if you don't.

['97ventureowner]

Originally Posted by mstbone67a

Is there a way to sticky this thread that has the link to
http://www.d-tips.com/General/Articl...sket/art10.art

Consider it done.

[mstbone67a]

awesome!!