Started the install last sunday night after coming home from from All GM Nats in Carlisle. All went well taking the LS1 off other than breaking the OPSU, which I kind of expected since I didn't know how things went together back there. Since everything was going pretty well I decided to go ahead and put the LS6 on even though it was getting late. (I should have called it a night at that point, but thats a lesson I learned the hard way)-->. So I get the LS6 in place (didnt realize my OPSU was broken at this point) and start torquing the bolts down in sequence (44in lbs 1st pass). I had just bought an inch lbs torque wrench at carlisle for a good deal (a craftsman, "brand new" apparently) and was waiting for the typical click sound when it reaches the correct torque. I never heard or felt anything from the wrench and since this was my first time using inch pounds for anything, I didnt know what to compare it to, but I could see the plastic studs that the bolts go into on the intake starting to bend and I thought "this can't be right!" So I loosened it a little and moved on to the next few bolts in the sequence with the same results. Finally I got to the front driver side bolt and torqued it down and rather than hearing a "click" I heard a "POP"! Broke the bolt in the head. Monday night: So I took it back off and tried drilling into the bolt to get the EZ out in and guess what? Broke the drill bit, inside the bolt, inside the head!!!!! Tuesday night: Had to use the hammer and chisel method to get the broken bolt out. I also discovered my broken OPSU (kind of a blessing in disguise i guess) and I called the dealer to order a new bolt and OPSU. They said they would have to order them but didnt say when they would come in. Wednesday: waiting for parts. Thursday: waiting for parts. Friday: waiting for parts. Saturday: waiting for parts. Sunday (1 week): still waiting but leaving for vacation tonight! IF the parst come in next week, the earliest I will be able to work on it will be next saturday!! Almost 2 weeks assuming there are no leaks or other problems!!!

I'm 18 years old and have learned a lot during this install from all of my mistakes, but DAMN! I just wanna drive my car again...

Like they say: **** happens

 

that sucks man, sounds like everything that could go wrong did.. im 17 and have been debating on whether to install an ls6 intake or not for a while now..

 

**** happens man. You learn a lot more by making mistakes even ifs its costly.

 

While the intake is still off you might want to replace your PCV hoses - or at least do a good inspection on them. Easy to do while the manifold is off. Fyi, I had a vacuum leak recently from a PCV line.

 

Yup. Easy as cake to get to with it on as well.

 

i put my car away in my parents garage this past winter, working on it little bit here and there on the weekends my fast 92/92 swap with AIR removal and EGR took 3 months . . . .

 

best way to learn, id rather screw up an intake mainfold install than a heads/cam ANYTHING internal install.

and def. check pcv system, they get old and brittle and crack on you when you move stuff around in that bay

 

watch the o-rings on the injectors!! if you crack one of those bastards you'll think all hell is breaking loose in your bottom end...

 

mine as well do the LS6 valley cover while you are there

 

gotta love those OPSU's! +1 on the pcv hoses.

 

So what's the trick to not break the OPSU? I am doing a FAST here soon so I want to learn from your mistakes too!

 

i didnt break my OPSU. just when you are pulling the manifold out stick ur arm all the way behind the manifold and lift the vaccum hose over the OPSU as u pull the manifold out. this worked for me pretty well. same thing when putting stuff back together.

 

^^^ I did the same thing pull it out a tiny bit reach back an pull the hose over it. Just take it slow don't be in a rush.

 

Damn man. Sounds like installing headers on my buddy's 98 Z28. Check out this thread for part of the story.

https://ls1tech.com/forums/generatio...ount-bolt.html

The rest of the story is fighting and waiting to get the correct ORY sent to us so we could finish the install. Live and learn, man. So goes life...

 

Damn man, my install took about 1.5 hours because I did alot of research and knew about the torquing and OPSU in the back. I guess it will be a lesson for next time about researching a lot!

 

Just go UP and out not out and up, worked for me.

 

Doin it for the first time is always challenging. after swappin manifolds countless times i can do it in less than 1/2 hour. Practice makes perfect

 

why change the valley cover?

 

It is revised so that you do not burn as much oil

 

I'm 18 but got lucky and am good friends with a gm master tech.....