intake gasket replacement
08-20-2005, 12:11 PM
#1
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Help Me!!! I am new to this website and I come with issues...my car is still a 2000 3.8 camaro and right now it has an uncontrolable fever. I had a diagnostics test done and pressure test done and I need to replace the intake gasket..will this be something a professional should do?
08-20-2005, 10:28 PM
#3
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3.8L Engine
Intake Manifold Replacement - Upper
Removal Procedure
1. Disconnect the intake air temperature (IAT) sensor electrical connector.
2. Remove the air intake duct.
3. Remove the drive belt tensioner.
4. Disconnect the fuel pressure regulator vacuum and EVAP emission canister purge harness from the following: Manifold vacuum source, Purge solenoid valve, Fuel pressure regulator valve
5. Disconnect the manifold vacuum source electrical connector.
6. Remove the manifold vacuum source screws.
7. Remove the manifold vacuum source from the upper intake manifold.
8. Disconnect the canister purge solenoid valve electrical connector and hose.
9. Remove the evaporative emissions canister purge solenoid valve.
10. Remove the idle air control (IAC) valve from the upper intake manifold.
11. Relieve the fuel pressure.
12. Disconnect the fuel feed pipe from the fuel rail.
13. Disconnect the fuel return pipe from the fuel rail.
14. Disconnect the EVAP pipe at the engine.
15. Remove the cruise control and accelerator control cables from the throttle body and bracket.
16. Remove the accelerator control cable bracket bolts and bracket.
17. Remove the ignition control module.
18. Remove the brake booster vacuum hose from the intake manifold fitting.
19. Remove the generator brace bolts.
20. Remove the generator brace from the lower intake manifold.
21. Disconnect the idle air control (IAC) valve electrical connector.
22. Disconnect the throttle position (TP) sensor electrical connector.
23. Disconnect the mass airflow (MAF) sensor electrical connector.
24. Remove the wiring harness from the rosebud clips at the fuel rail.
25. Remove the throttle body from the upper intake manifold.
26. Remove the thermostat and thermostat housing.
27. Disconnect the fuel injector electrical connectors. Important: Clean the dirt out of the injector bores with compressed air.
28. Remove the fuel rail nuts.
29. Remove the fuel rail.
30. Remove the upper intake manifold bolts.
31. Remove the upper intake manifold.
32. Remove the upper intake manifold gasket.
Installation Procedure
1. Install the upper intake manifold gasket.
2. Install the upper intake manifold.
3. Install the upper intake manifold bolts. [see attached diagram] Tighten in sequence the vertical intake manifold bolts (1-10) to 15 N·m (11 lb ft). Tighten the two water outlet bolts (11) to 27 N·m (20 lb ft). Tighten the side bolts (12, 13) to 30 N·m (22 lb ft).
4. Perform the following to install the fuel rail to the upper intake manifold: Using clean engine oil, lubricate the fuel injector O-rings. Install the injectors into the bores of the manifold. Carefully press the fuel rail down with the palms of both hands until the injectors are fully seated.
5. Install the fuel rail nuts. Tighten the fuel rail nuts to 8.5 N·m (75 lb in).
6. Connect the fuel injector electrical connectors.
7. Install the thermostat and thermostat housing.
8. Install the throttle body to the upper intake manifold studs.
9. Install the throttle body bolt and nuts. Tighten the throttle body bolt to 10 N·m (89 lb in). Tighten the throttle body nuts to 10 N·m (89 lb in).
10. Install the wiring harness to the rosebud clips on the fuel rail.
11. Connect the mass airflow (MAF) sensor electrical connector.
12. Connect the throttle position (TP) sensor electrical connector.
13. Connect the idle air control (IAC) valve electrical connector.
14. Install the generator brace to the upper intake manifold.
15. Install the generator brace bolts. Tighten the generator brace bolts to 25 N·m (18 lb ft).
16. Install the brake booster vacuum hose to the intake manifold fitting.
17. Install the ignition control module.
18. Install the accelerator control cable bracket and bracket bolts. Tighten the accelerator control cable bracket bolts to 16 N·m (12 lb ft).
19. Install the accelerator control and cruise control cables to the throttle body and bracket.
20. Connect the EVAP pipe at the engine.
21. Connect the fuel return pipe to the fuel rail.
22. Connect the fuel feed pipe to the fuel rail.
23. Install the idle air control (IAC) valve to the upper intake manifold.
24. Install the evaporative emissions canister purge solenoid valve.
25. Connect the canister purge solenoid valve electrical connector and hose.
26. Install the manifold vacuum source to the upper intake manifold.
27. Install the manifold vacuum source screws. Tighten the manifold vacuum source screws to 10 N·m (89 lb in).
28. Connect the manifold vacuum source electrical connector.
29. Connect the fuel pressure regulator vacuum and EVAP emission canister purge harness to the following: Manifold vacuum source, Purge solenoid valve, Fuel pressure regulator valve
30. Install the drive belt tensioner.
31. Install the air intake duct.
32. Connect the intake air temperature (IAT) sensor electrical connector.
Intake Manifold Replacement - Lower
Removal Procedure
Important: Remove the upper intake manifold in order to uncover hidden bolts on the front and left rear corners of the lower intake manifold.
1. Remove the upper intake manifold. Refer to Intake Manifold Replacement .
2. Remove the engine coolant temperature sensor.
3. Remove the lower intake manifold bolts.
4. Remove the lower intake manifold.
5. Remove the lower intake manifold gaskets and seals.
Installation Procedure
1. Apply GM P/N 12345336 or equivalent to both the front and rear intake manifold seals.
2. Install the intake manifold gaskets and seals.
3. Install the lower intake manifold.
4. Install the lower intake manifold bolts.
Important: The two lower intake manifold bolts are located under the upper intake manifold. They must be installed before the upper intake manifold.
5. Apply GM P/N 12345493 or equivalent thread lock compound to the bolt threads before installing.
6. Torque the lower intake bolts to specifications. [see attached diagram] Tighten the lower manifold bolts in sequence as shown to 15 N·m (11 lb ft).
7. Install the engine coolant temperature sensor.
8. Install the upper intake manifold.
Intake Manifold Replacement - Upper
Removal Procedure
1. Disconnect the intake air temperature (IAT) sensor electrical connector.
2. Remove the air intake duct.
3. Remove the drive belt tensioner.
4. Disconnect the fuel pressure regulator vacuum and EVAP emission canister purge harness from the following: Manifold vacuum source, Purge solenoid valve, Fuel pressure regulator valve
5. Disconnect the manifold vacuum source electrical connector.
6. Remove the manifold vacuum source screws.
7. Remove the manifold vacuum source from the upper intake manifold.
8. Disconnect the canister purge solenoid valve electrical connector and hose.
9. Remove the evaporative emissions canister purge solenoid valve.
10. Remove the idle air control (IAC) valve from the upper intake manifold.
11. Relieve the fuel pressure.
12. Disconnect the fuel feed pipe from the fuel rail.
13. Disconnect the fuel return pipe from the fuel rail.
14. Disconnect the EVAP pipe at the engine.
15. Remove the cruise control and accelerator control cables from the throttle body and bracket.
16. Remove the accelerator control cable bracket bolts and bracket.
17. Remove the ignition control module.
18. Remove the brake booster vacuum hose from the intake manifold fitting.
19. Remove the generator brace bolts.
20. Remove the generator brace from the lower intake manifold.
21. Disconnect the idle air control (IAC) valve electrical connector.
22. Disconnect the throttle position (TP) sensor electrical connector.
23. Disconnect the mass airflow (MAF) sensor electrical connector.
24. Remove the wiring harness from the rosebud clips at the fuel rail.
25. Remove the throttle body from the upper intake manifold.
26. Remove the thermostat and thermostat housing.
27. Disconnect the fuel injector electrical connectors. Important: Clean the dirt out of the injector bores with compressed air.
28. Remove the fuel rail nuts.
29. Remove the fuel rail.
30. Remove the upper intake manifold bolts.
31. Remove the upper intake manifold.
32. Remove the upper intake manifold gasket.
Installation Procedure
1. Install the upper intake manifold gasket.
2. Install the upper intake manifold.
3. Install the upper intake manifold bolts. [see attached diagram] Tighten in sequence the vertical intake manifold bolts (1-10) to 15 N·m (11 lb ft). Tighten the two water outlet bolts (11) to 27 N·m (20 lb ft). Tighten the side bolts (12, 13) to 30 N·m (22 lb ft).
4. Perform the following to install the fuel rail to the upper intake manifold: Using clean engine oil, lubricate the fuel injector O-rings. Install the injectors into the bores of the manifold. Carefully press the fuel rail down with the palms of both hands until the injectors are fully seated.
5. Install the fuel rail nuts. Tighten the fuel rail nuts to 8.5 N·m (75 lb in).
6. Connect the fuel injector electrical connectors.
7. Install the thermostat and thermostat housing.
8. Install the throttle body to the upper intake manifold studs.
9. Install the throttle body bolt and nuts. Tighten the throttle body bolt to 10 N·m (89 lb in). Tighten the throttle body nuts to 10 N·m (89 lb in).
10. Install the wiring harness to the rosebud clips on the fuel rail.
11. Connect the mass airflow (MAF) sensor electrical connector.
12. Connect the throttle position (TP) sensor electrical connector.
13. Connect the idle air control (IAC) valve electrical connector.
14. Install the generator brace to the upper intake manifold.
15. Install the generator brace bolts. Tighten the generator brace bolts to 25 N·m (18 lb ft).
16. Install the brake booster vacuum hose to the intake manifold fitting.
17. Install the ignition control module.
18. Install the accelerator control cable bracket and bracket bolts. Tighten the accelerator control cable bracket bolts to 16 N·m (12 lb ft).
19. Install the accelerator control and cruise control cables to the throttle body and bracket.
20. Connect the EVAP pipe at the engine.
21. Connect the fuel return pipe to the fuel rail.
22. Connect the fuel feed pipe to the fuel rail.
23. Install the idle air control (IAC) valve to the upper intake manifold.
24. Install the evaporative emissions canister purge solenoid valve.
25. Connect the canister purge solenoid valve electrical connector and hose.
26. Install the manifold vacuum source to the upper intake manifold.
27. Install the manifold vacuum source screws. Tighten the manifold vacuum source screws to 10 N·m (89 lb in).
28. Connect the manifold vacuum source electrical connector.
29. Connect the fuel pressure regulator vacuum and EVAP emission canister purge harness to the following: Manifold vacuum source, Purge solenoid valve, Fuel pressure regulator valve
30. Install the drive belt tensioner.
31. Install the air intake duct.
32. Connect the intake air temperature (IAT) sensor electrical connector.
Intake Manifold Replacement - Lower
Removal Procedure
Important: Remove the upper intake manifold in order to uncover hidden bolts on the front and left rear corners of the lower intake manifold.
1. Remove the upper intake manifold. Refer to Intake Manifold Replacement .
2. Remove the engine coolant temperature sensor.
3. Remove the lower intake manifold bolts.
4. Remove the lower intake manifold.
5. Remove the lower intake manifold gaskets and seals.
Installation Procedure
1. Apply GM P/N 12345336 or equivalent to both the front and rear intake manifold seals.
2. Install the intake manifold gaskets and seals.
3. Install the lower intake manifold.
4. Install the lower intake manifold bolts.
Important: The two lower intake manifold bolts are located under the upper intake manifold. They must be installed before the upper intake manifold.
5. Apply GM P/N 12345493 or equivalent thread lock compound to the bolt threads before installing.
6. Torque the lower intake bolts to specifications. [see attached diagram] Tighten the lower manifold bolts in sequence as shown to 15 N·m (11 lb ft).
7. Install the engine coolant temperature sensor.
8. Install the upper intake manifold.
08-22-2005, 02:27 PM
#4
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Location: Texas...that says it all
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This is just what I was looking for...right now my car is relaxing in the backyard. I will start this project first thing Saturday Morning and will keep you updated...
08-27-2005, 06:29 PM
#6
TECH Veteran
Originally Posted by camracingah
ACW...Just want to send my thanks your way..as I previously stated my car got all taken care of thanks to your help...Thank You...
06-17-2009, 10:24 PM
#7
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I know this is bring this thread back from the dead, but I am currently doing this job now. I am down to the lower intake and I have 11 bolts off, I am having trouble finding the last one. I think the one that i didnt get is either 7 or 10. I only saw one bolt in that area and I got all of the other ones off. I tried to pull out the lower intake but it doesnt budge so i know theres still one bolt on there. Please help.
