Replacing Chevrolet Lower Intake Manifold Gasket

Introduction: Replacing Chevrolet Lower Intake Manifold Gasket

About: I am a teacher who enjoys environmentally responsible woodworking. Most evenings will find me in the shop working with my now 8 year old son Shay who is both my greatest helper and biggest fan.

This issue is so common on GM cars 1996-2003 it is almost cliche.  I am not saying you could or should fix it yourself but I figure by doing it myself I saved nearly $500 easy.  It wasn't that hard and if I had had my own video to give me tips before starting I could have shaved 2 hours off the total time in addition to less hassle.  What you do is your own business and responsibility but should you decide to emulate me and have questions ask them via youtube comments as I will be more likely to respond quickly.

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    9 years ago on Introduction

    I'm a little sorry, but I didn't watch the video yet. These things are really common to fail. I personally have a couple of tips that may be addressed in the video:

    1.) Use FelPro gaskets instead of OEM. FelPro makes a lower intake set that includes METAL gaskets. To make sure that you are buying the metal gaskets when you are at the parts store, be sure the part number ends with a "T". This signifies that they are the updated metal gaskets.

    2.)GM has been using this design intake much longer than 1996. This engine was introduced in 1980 as a 2.8L ( and coincidentally is the first metric engine that GM ever produced).

    3.) Be sure to replace the distributor o-ring, or oil pump drive o-ring depending on the year. This really sucks with the intake manifold on the car.

    4.) Make sure that you re-install the push rods in the correct order. There are 2 different lengths. ( I think the exhaust push rods are the longer ones).

    5.) Mind the position of the spark plug wires (cords). The firing order is 1-2-3-4-5-6, but the wires do not install on the coils that way. The factory coils have the numbers on them, but replacement ones do not. I think the order is 1-4-2-5-3-6, but that is kind of off the hip. I cam to that conclusion due to the fact that it uses "waste spark."

    Sorry to be long winded, but this is the last one.

    6.) Put "Loctite" on the lower intake bolts. The torque specification on the bolts is really low, maybe 12"/lbs. Loctite makes sure that the bolts do not loosen up through normal use.

    Good luck, remember to pay attention and you will be fine.