Question about 1989 Pontiac Firebird

1 Answer

Removing the heads

Do you have to pull the distributor to pull off the intake manifold on the 305 engine? can someone provide the procedure step by step after disconnecting the wires and vacuum lines from the TBI

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No one will spend the time to discribe all you want to know. I did all you are doing in the 1960's muscle car era with no experience. Read study use internet hangout with car guys and learn. Answer: Pull the dist if in the way or through hole in manifold

Posted on Sep 26, 2009

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1 Answer

How do I remove intake manifold from a 1974 cadillac eldorado


Pull the distributor & remove the intake manifold bolts

Doesn't sound as though vehicle repairs are your area
of expertise,best forget it or pay someone

Apr 24, 2014 | 1974 Cadillac Eldorado

1 Answer

Diy headgaskit leaking


which engine,there are many , state displacement and cylinder count.
DID YOU OVERHEAT IT?
this is covered in the FSM, get one.
or use Alldata.com
lots of steps.
well over 100..... counting adjustements, etc.....
i guess you never done a head job before?

do not just replace it. (gasket) check for head AND engine
deck warpage. ( a $2 tool , )
here is my wild guess,

Except Accord V-6 The cylinder head temperature must be below 100F (38C); allow the engine to cool several hours if the car has been recently driven. Turn the crankshaft pulley so that the number one piston is at Top Dead Center (TDC) of the compression stroke.
  1. Disconnect the battery ground cable.
  2. Drain the cooling system.
  3. Remove the air cleaner and intake duct assembly.
  4. Label and remove the brake booster, PCV and charcoal canister vacuum hoses from the intake manifold.
  5. Remove the engine ground cable from the cylinder head or valve cover.
  6. Relieve the fuel pressure using the proper procedure. Disconnect the fuel lines.
  7. Disconnect the accelerator cable at the throttle body or carburetor. On automatic transaxle vehicles, also disconnect the throttle control cable.
  8. Disconnect and tag all the wire harnesses and vacuum hoses from the cylinder head, intake manifold and throttle body/carburetor. Disconnect the spark plug wires, then position them aside.
  9. Disconnect the upper radiator hose. Remove the heater hoses from the cylinder head.
  10. If equipped, remove the cruise control actuator. Do not disconnect the cable; move the actuator out of the work area with the cable attached.
  11. Remove accessory drive belts.
  12. Disconnect the inlet hose from the power steering pump and plug the hose immediately to prevent fluid leakage. Remove the power steering pump from the cylinder head and position it aside.
When the power steering hose is disconnected, the fluid will flow out. Cover the alternator with a shop towel to prevent the fluid from leaking into it.
  1. If the alternator is mounted to the cylinder head, remove it.
  2. Remove the power steering and alternator brackets if they are mounted on the cylinder head.
  3. Remove the distributor. Be sure to scribe a line relating the position of the distributor to the engine for easy installation.
  4. If equipped, remove the cylinder sensor next to the distributor.
  5. Remove the valve cover.
  6. Remove the timing belt.
Do not crimp or bend the timing belt.
  1. Remove the exhaust header pipe nuts and the header pipe bracket (if equipped). Pull the pipe away from the exhaust manifold.
  2. If equipped, remove the EGR crossover and air suction pipes.
  3. On Accords through 1989 and Preludes through 1991, the cylinder head can be removed with the intake and exhaust manifolds either still attached or removed. On other models, the manifolds should be removed first.
  4. On some engines, it will be necessary to remove the camshaft holders, camshafts and rocker arms to access the cylinder head bolts. If so, refer to the proper procedures in this section.
  5. Remove the cylinder head bolts in sequence (take notice of any bolt holes occupied by longer bolts). Failure to follow this procedure may cause the head to warp.
    1. On 1984-89 Accords and 1984-91 Preludes, work from the ends toward the center. Loosen each bolt about 1/2 turn each time and make several passes to release the tension evenly.
    2. On 1990-95 Accords and 1992-95 Preludes, follow the loosening sequence shown in the illustrations. Loosen each bolt about 1/3 turn each time. Repeat the sequence until all bolts are loosened.
Remove the cylinder head. The head may resist removal, even with the bolts out. Tap the edge of the head with a plastic or rubber mallet; lift the head straight up to remove it.
Remove the cylinder head gasket and clean the mating surfaces.
(do not use wire brush or metal scrapers on alum, heads)
use a plastic scraper.
then check for warping, (ask)

If applicable, remove the intake and exhaust manifolds from the cylinder head. (lol, is listed last, gotta love non FSM real online data)


i post this to dissuade you, its not complete.
there are many factors,checks and issues, TTY, and others.....
graphics missing above, head sequence rules. on and off !

if the head was overheated, you need to get it pressure tested
and warp checked.
the top to reasons for new gaskets , put on to fail in first 10k milles
is , not warp checked, pressure checked)
or 2: surfaces were not good. (might need to be milled a tad)
3: not using new head bolts, some are TTY and if not ,should not be used 3 times.

Dec 26, 2013 | 1993 Honda Accord

1 Answer

I NEED replace head gaske


Hi there:Removal and InstallationExcept Accord V-6


The cylinder head temperature must be below 100 degrees F (38 degrees C); allow the engine to cool several hours if the car has been recently driven. Turn the crankshaft pulley so that the number one piston is at Top Dead Center (TDC) of the compression stroke.

  1. Disconnect the battery ground cable.
  2. Drain the cooling system.
  3. Remove the air cleaner and intake duct assembly.
  4. Label and remove the brake booster, PCV and charcoal canister vacuum hoses from the intake manifold.
  5. Remove the engine ground cable from the cylinder head or valve cover.
  6. Relieve the fuel pressure using the proper procedure. Disconnect the fuel lines.
  7. Disconnect the accelerator cable at the throttle body or carburetor. On automatic transaxle vehicles, also disconnect the throttle control cable.
  8. Disconnect and tag all the wire harnesses and vacuum hoses from the cylinder head, intake manifold and throttle body/carburetor. Disconnect the spark plug wires, then position them aside.
  9. Disconnect the upper radiator hose. Remove the heater hoses from the cylinder head.
  10. If equipped, remove the cruise control actuator. Do not disconnect the cable; move the actuator out of the work area with the cable attached.
  11. Remove accessory drive belts.
  12. Disconnect the inlet hose from the power steering pump and plug the hose immediately to prevent fluid leakage. Remove the power steering pump from the cylinder head and position it aside.

When the power steering hose is disconnected, the fluid will flow out. Cover the alternator with a shop towel to prevent the fluid from leaking into it.

  1. If the alternator is mounted to the cylinder head, remove it.
  2. Remove the power steering and alternator brackets if they are mounted on the cylinder head.
  3. Remove the distributor. Be sure to scribe a line relating the position of the distributor to the engine for easy installation.
  4. If equipped, remove the cylinder sensor next to the distributor.
  5. Remove the valve cover.
  6. Remove the timing belt.

Do not crimp or bend the timing belt.

  1. Remove the exhaust header pipe nuts and the header pipe bracket (if equipped). Pull the pipe away from the exhaust manifold.
  2. If equipped, remove the EGR crossover and air suction pipes.
  3. On Accords through 1989 and Preludes through 1991, the cylinder head can be removed with the intake and exhaust manifolds either still attached or removed. On other models, the manifolds should be removed first.
  4. On some engines, it will be necessary to remove the camshaft holders, camshafts and rocker arms to access the cylinder head bolts. If so, refer to the proper procedures in this section.
  5. Remove the cylinder head bolts in sequence (take notice of any bolt holes occupied by longer bolts). Failure to follow this procedure may cause the head to warp.
    1. On 1984-89 Accords and 1984-91 Preludes, work from the ends toward the center. Loosen each bolt about 1 / 2 turn each time and make several passes to release the tension evenly.
    2. On 1990-95 Accords and 1992-95 Preludes, follow the loosening sequence shown in the illustrations. Loosen each bolt about 1/3 turn each time. Repeat the sequence until all bolts are loosened.

3_5_2012_9_19_50_pm.gif
Fig. 1: Bolt loosening sequence on 1990-93 Accords and 1992-95 Preludes with 2.2L engines

24. Remove the cylinder head. The head may resist removal, even with the bolts out. Tap the edge of the head with a plastic or rubber mallet; lift the head straight up to remove it.
  1. Remove the cylinder head gasket and clean the mating surfaces.
  1. If applicable, remove the intake and exhaust manifolds from the cylinder head.

To install:
  1. Install a new head gasket on the engine, making certain it is positioned correctly. The cylinder head dowel pins and the oil jet must be in place. Refer to the illustrations if necessary.
  2. Install the head. Lower it straight down onto the block, aligning it correctly.
  3. Apply clean engine oil to the bolt threads and the contact face of the bolt head. Install the head bolts finger-tight.
  4. On all models except 1988-89 DOHC Prelude and 1992-95 Preludes with 2.3L and VTEC engines, tighten the head bolts following sequence A. On 1988-89 DOHC Preludes, use sequence B. Use sequence C on 1992-95 Preludes with 2.3L and VTEC engines.
    1. On 1984-89 Accords and 1984-91 Preludes, tighten the bolts in two passes. The first pass should bring the bolts to about 22 ft. lbs. (30 Nm). On the second pass, tighten the bolts to their final torque of 49 ft. lbs. (68 Nm).
    2. On 1990-93 Accords, tighten the bolts to 29 ft. lbs. (40 Nm) on the first pass, 51 ft. lbs. (70 Nm) on the second pass, then tighten the bolts to their final torque of 78 ft. lbs. (108 Nm).
    3. On 1994-95 Accords and 1992-95 Preludes, the bolts are also tightened in three passes. Tighten the bolts to 29 ft. lbs. (40 Nm) on the first pass, 51 ft. lbs. (70 Nm) on the second pass, then tighten the bolts to their final torque of 72 ft. lbs. (100 Nm).
    .
3_5_2012_9_24_01_pm.jpg
Fig. Cylinder head bolt torque sequence B

3_5_2012_9_24_44_pm.jpg
Fig. Cylinder head bolt torque sequence B

3_5_2012_9_25_06_pm.jpg
Fig. Cylinder head bolt torque sequence C

  1. If applicable, assemble the intake and exhaust manifolds to the head. Use new gaskets.
  2. If applicable, install the cam, rockers and camshaft holders.
  3. If equipped, install the EGR crossover and air suction pipes.
  4. Connect the exhaust pipe to the manifold using new nuts.
  5. Install the timing belt.
  6. Install the valve cover.
  7. Install the cylinder sensor (if equipped) and the distributor.
  8. If applicable, install the alternator.
  9. Install the power steering pump, then connect the inlet hose to the pump.
  10. Install the accessory drive belts. Adjust the belt tensions.
  11. Install the heater hoses.
  12. Install the cruise control actuator if it was removed.
  13. Connect the spark plug wires. Connect all the wire harnesses and vacuum hoses to the cylinder head, intake manifold and throttle body/carburetor.
  14. Connect the throttle control cable and/or accelerator cable at the throttle body.
  15. Connect the fuel lines.
  16. Install the brake booster, PCV and charcoal canister vacuum hoses.
  17. Install the air cleaner and intake duct.
  18. Refill the engine coolant. It is recommended that the engine oil be changed whenever a cylinder head is removed.
  19. Connect the negative battery cable.
  20. Start the engine, allowing it to idle. Bleed the cooling system. Check the work area carefully for any signs of fluid leakage or any indication of the timing belt rubbing or slapping the covers

Hope this helps; also keep in mind that your feedback is important and I`ll appreciate your time and consideration if you leave some testimonial comment about this answer.
Thank you for using FixYa.

Mar 05, 2012 | 1993 Honda Accord

1 Answer

How to replace head gasket on 4 cylander


2.6L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Drain the cooling system.
  3. Relieve the fuel system pressure.
  4. Remove or disconnect the following:
    • Negative battery cable
    • Hood
    • Accessory drive belts
    • Accelerator cable
    • Positive Crankcase Ventilation (PCV) valve and hose
    • Air intake duct
    • Fuel pressure regulator vacuum line
    • Canister hose
    • Brake booster vacuum line
    • Engine wiring harness connectors at right wheel housing
    • Ground cable connector at the intake manifold, starter and firewall
    • Heated Oxygen (HO2S) sensor connector
    • Alternator wiring connectors
    • Oil pressure switch connector
    • Starter motor harness connectors
    • Ignition coil connector
    • Spark plug wires
    • Distributor
    • Exhaust front pipe
    • Exhaust Gas Recirculation (EGR) gas temperature sensor connector
    • Air pump
    • EGR pipe
    • Heat shield
    • Exhaust manifold
    • Throttle Position (TP) switch connector
    • Cooling fan
    • Water pump pulley
    • Power steering pump
    • Intake manifold
    • Crankshaft pulley
    • Front cover
    • Timing belt. Refer to the Timing Belt unit repair section.
    • Valve cover
    • Rocker arms
    • Camshaft
    • Cylinder head
Cylinder head bolt loosening sequence - 2.6L engine

tecnovative_96.gif
  1. To install:
  2. NOTE: Refer to Section 1 of this manual for the cylinder head torque sequence illustration. The illustration is located after the Torque Specification Chart.
  3. NOTE: Lubricate the cylinder head bolts with clean engine oil for assembly.
  4. Install the cylinder head with a new gasket. Tighten the bolts in sequence as follows:
  5. Step 1: 58 ft. lbs. (75 Nm)
  6. Step 2: 72 ft. lbs. (98 Nm)
    1. Install or connect the following:
    2. Camshaft
    • Rocker arms
    • Valve cover
    • Timing belt
    • Front cover
    • Crankshaft pulley. Tighten the bolt to 87 ft. lbs. (128 Nm).
    • Intake manifold
    • Power steering pump
    • Water pump pulley
    • Cooling fan
    • TP switch connector
    • Exhaust manifold
    • Heat shield
    • EGR pipe
    • Air pump
    • EGR gas temperature sensor connector
    • Exhaust front pipe
    • Distributor
    • Spark plug wires
    • Ignition coil connector
    • Starter motor harness connectors
    • Oil pressure switch connector
    • Alternator wiring connectors
    • HO2S sensor connector
    • Ground cable connector at the intake manifold, starter and firewall
    • Engine wiring harness connectors at right wheel housing
    • Brake booster vacuum line
    • Canister hose
    • Fuel pressure regulator vacuum line
    • Air intake duct
    • PCV valve and hose
    • Accelerator cable
    • Accessory drive belts
    • Hood
    • Negative battery cable
    1. Fill the cooling system.
    2. Start the engine and check for leaks.

    tecnovative_65.jpg

    Feb 05, 2011 | 1997 Isuzu Rodeo

    1 Answer

    How to replace an intake manifold gasket on a 1996 gmc jimmy


    Hello,

    Here is a detailed summary on the procedure of how to replace the intake manifold gasket on a 1996 gmc jimmy;
    REMOVING THE UPPER INTAKE MANIFOLD(PLENUM)
    STEP 1 Disconnect Battery (may not be absolutely necessary, but a good practice to avoid shorting a positive wire to ground).


    STEP 2 Remove serpentine belt.

    STEP 3 Drain the coolant.

    STEP 4 Remove air cleaner ducting and disconnect wires.

    STEP 5 Disconnect throttle linkage and bracket.

    STEP 6 Disconnect cruise control cable.

    STEP 7 Remove brake booster vacuum hose at manifold.

    STEP 8 Remove PCV hose.

    STEP 9 Remove ignition coil and bracket.

    STEP 1O Remove purge solenoid and bracket.

    STEP 11 Relieve fuel pressure at test port.

    STEP 12 Remove fuel lines and bracket.

    STEP 13 Remove upper intake manifold.

    REMOVING THE LOWER INTAKE MANIFOLD
    STEP 1 Remove the distributor and label the spark plug wires.

    STEP 2 Remove heater hoses and bypass hose.

    STEP 3 Remove upper radiator hose.


    STEP 4 Remove EGR valve?

    STEP 5 Remove sensors and bracket on right side.

    STEP 6 Remove EGR tube, clamp and bolt.

    STEP 7 Remove PCV valve (and replace).

    STEP 8 Unbolt A/C compressor and move it aside.

    STEP 9 Loosen compressor bracket and slide forward, but do not remove it.

    STEP 10 Remove alternator bracket bolt (or remove alternator and set aside)

    STEP 11 Unplug all vacuum lines from intake manifold.


    STEP 12 Unplug all electrical connectors from manifold.

    STEP 13 Take note of the intake manifold bolts and mark the location of the bolts.


    STEP 14 Remove intake manifold bolts, and manifold.

    STEP 15 Clean mating surfaces

    THE MAIN INSTALLATION
    STEP1 Set the new gaskets in place and apply silicone to flat areas on front and rear of engine block.

    STEP2 Apply thread locking compound to manifold bolts.

    STEP 3 Install the manifold and tighten bolts to 35 ft-lbs, in proper sequence.

    STEP4 Install the distributor.

    STEP5 Install the upper intake manifold.



    The remaining installation procedures are basically the reverse of removal.


    Have a nice day.

    Dec 04, 2010 | 1996 GMC Jimmy

    1 Answer

    How do i replace the head gasket in a 2000 dodge durango.


    3.9L, 5.2L, and 5.9L Engines To Remove:
    3.9L Engine dod_trk_39l_cylinder_head.gif
    1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
    2. Remove or disconnect the following:
      • Battery negative cable
      • Coolant
      • Intake manifold-to-alternator bracket support rod
      • Alternator
      • Closed crankcase ventilation system
      • Evaporation control system
      • Air cleaner, air in-let hose and resonator
    3. Release fuel system pressure.
    4. Remove or disconnect the following:
      • Fuel supply line from the fuel rail
      • Accelerator linkage and, the speed control and transmission kickdown cables (if equipped)
      • Distributor cap and wires
      • Coil wires
      • Coolant temperature sending unit wire
      • Heater hoses and bypass hose
      • Vacuum supply hoses from the intake manifold (3.9L Engine)
      • Fuel injector harness and secure out of the way (3.9L Engine)
      • Cylinder head covers and gaskets
      • Intake manifold and throttle body as an assembly
      • Exhaust manifolds
      • Rocker arm assemblies and push rods, and identify to ensure installation in original locations.
      • Head bolts from each cylinder head and remove cylinder heads
      • Spark plugs
    To Install:
    1. Install or connect the following:
      • New cylinder head gaskets into position on the cylinder block
      • Cylinder heads onto head gaskets and cylinder block
    2. Tighten all cylinder head bolts, starting at top center and in sequence
      1. Torque to: 50 ft. lbs. (68 Nm)
      2. Repeat and Torque to: 105 ft. lbs. (143 Nm)
      CAUTION
      When tightening the rocker arm bolts, ensure that the piston in that cylinder is NOT at TDC.
    3. Install or connect the following:
      • Push rods and rocker arm assemblies in their original positions.
        1. Torque to: 21 ft. lbs. (28 Nm)
      • Intake manifold and throttle body assembly
      • Exhaust manifolds
      • Spark plugs
        1. Torque to: 30 ft. lbs. (41 Nm)
      • Coil wires
      • Coolant temperature sending unit wire
      • Fuel injector harness (3.9L Engine)
      • Vacuum supply hoses to the intake manifold (3.9L Engine)
      • Heater hoses and bypass hose
      • Distributor cap and wires
      • Accelerator linkage and the speed control and transmission kickdown cables
      • Fuel supply line.
      • Alternator and accessory drive belt.
        1. Alternator bolt - Torque to: 30 ft. lbs. (41 Nm)
      • Intake manifold-to-alternator bracket support rod and bolts
      • Cylinder head covers
      • Closed crankcase ventilation system
      • Evaporation control system
      • Resonator assembly (3.9L Engine), air in-let hose and air cleaner
      • Heat shields
        1. Torque to: 30 ft. lbs. (41 Nm)
      • Coolant
      • Negative battery cable.
    prev.gif next.gif

    Oct 14, 2010 | 2000 Dodge Durango

    3 Answers

    How do I remove the head? (Blown Head gasket)


    prev.gif next.gif Cylinder Head REMOVAL & INSTALLATION 2.3L Engine
    1. Properly relieve the fuel system pressure.
    2. Disconnect the negative battery cable, then drain cooling system into a suitable container.
    3. Detach the heater inlet and throttle body heater hoses from water outlet. If accessible at this time, disconnect the upper radiator hose from the water outlet.
    4. Remove the exhaust manifold. For details, please refer to the procedure located in this section.
    5. Remove the intake (camshaft housing for SOHC) and exhaust (DOHC only) camshaft housings.
    6. Unfasten the oil fill tube bolt/screw then remove the oil fill cap and level indicator assembly. Pull the oil fill tube upward to unseat from block.
    7. Label and disengage the injector harness electrical connector.
    8. Detach the throttle body-to-air intake duct.
    9. Tag and disconnect the power brake vacuum hose from the throttle body.
    10. Remove the throttle cable bracket.
    11. Remove the throttle body from the intake manifold with the electrical harness and throttle cable attached and position the assembly aside.
    12. Tag and disconnect the MAP sensor vacuum hose from the intake manifold, then remove the intake manifold brace.
    13. Detach the electrical connectors from the MAP sensor, IAT sensor and the EVAP canister purge solenoid.
    14. If not already done, detach the upper (inlet) radiator hose from the water outlet.
    15. Disengage the coolant temperature sensor connector(s).
    16. Unfasten the cylinder head bolts in reverse order of the installation sequence shown in the accompanying figures.
    17. Lift the cylinder head from the engine block. Remove and discard the gasket. Inspect the oil flow check valve for freedom of movement.
    18. Using a suitable solvent, thoroughly clean and dry all bolts, bolt holes and mating surfaces. Inspect the head bolts for any damage and replace, if necessary. If using a scraper to clean the old gasket material from the mating surfaces, use only a plastic or wood one, NOT a metal scraper. Do NOT allow any debris to fall into the engine! To install:
    19. Place a new cylinder head gasket on the cylinder block, then carefully position the cylinder head in place.
    20. Sparingly coat the head bolt threads with clean engine oil, then allow the oil to drain off before installing.
    21. On 1988-89 engines, install and tighten the cylinder head bolts, in sequence, as follows:
      • Step 1 - Tighten all head bolts in sequence to 26 ft. lbs. (35 Nm)
      • Step 2 - Using a torque angle meter, tighten the short bolts an additional 80°and the long bolts an additional 90°in sequence Fig. 5: Cylinder head bolt tightening sequence - 1988-89 2.3L engine 86883121.gif
    22. On 1990-91 engines, tighten the cylinder head bolts, in sequence, as follows:
      • Step 1 - Tighten all head bolts in sequence to 26 ft. lbs. (35 Nm)
      • Step 2 - Using a torque angle meter, tighten the short bolts an additional 100°and the long bolts an additional 110°in sequence Fig. 6: Cylinder head bolt tightening sequence - 1990-91 2.3L engine 86883122.gif
    23. On 1992 engines, tighten the cylinder head bolts, in sequence, as follows:
      • Step 1 - Tighten, in sequence, head bolts 1-6 to 26 ft. lbs. (35 Nm), 7-8 to 15 ft. lbs. (20 Nm) and 9-10 to 22 ft. lbs. (30 Nm).
      • Step 2 - Tighten all head bolts, in sequence, an additional 90°using J 36660 or equivalent
      • Step 3 - In sequence, loosen each bolt one turn, then immediately re-tighten to the specified torque
      • Step 4 - After completing step 3 on all 10 bolts, tighten each bolt, in sequence, an additional 90° Fig. 7: Cylinder head bolt tightening sequence - 1992 2.3L engine 86883123.gif
    24. On 1993-95 vehicles, tighten the cylinder head bolts to the specifications shown in the accompanying figures. Fig. 8: Cylinder head bolt tightening sequence and specifications - 1993 2.3L engine 86883124.gif
      Fig. 9: Cylinder head bolt tightening sequence and specifications - 1994-95 2.3L engine 86883125.gif
    25. Engage the coolant temperature sensor electrical connector(s).
    26. Connect the upper radiator hose to the water outlet.
    27. Install the intake manifold bracket.
    28. Attach the following electrical connections: MAP sensor, IAT sensor, and the purge solenoid.
    29. Using a new gasket, install the throttle body to the intake manifold.
    30. Install the accelerator control cable bracket.
    31. Connect the throttle body-to-air intake duct.
    32. Install the oil fill tube and level indicator.
    33. Install the camshaft housing(s).
    34. Install the exhaust manifold. For details, please refer to the procedure located in this section.
    35. Connect the heater inlet and throttle body heater hoses to the water outlet.
    36. Fill all fluids to their proper levels.
    37. Connect the battery cable, start the engine and check for leaks.

    Sep 24, 2010 | 1992 Oldsmobile Achieva

    1 Answer

    Torque sequence for 1996 chevrolet van intake manifold with a 4.3 litre moter


    Ha, you tried to fool me with the bit about a 3.5 L motor--I could find that one...here is the complete procedure from AutoZone.com:




    Installation To install:
    1. Clean the gasket mounting surfaces. Be sure to inspect the manifold for warpage and/or cracks. If necessary, replace it.
    2. Position the gaskets on the cylinder head with the port blocking plates to the rear and the This Side Up stamps facing upward. Then apply a 3 / 16 in. (5mm) bead of RTV sealant on the front and rear of the engine block at the block-to-manifold mating surface. Extend the bead 1 / 2 in. (13mm) up each cylinder head to seal and retain the gaskets.

      0996b43f80208c7b.jpg enlarge_icon.gifenlarge_tooltip.gif Fig. Lower intake manifold tightening sequence-4.3L engines
    3. Install the lower intake manifold. Tighten the bolts in sequence and in 3 steps, as follows:


      1. Step 1: 26 inch lbs. (3 Nm).
      2. Step 2: 106 inch lbs. (12 Nm).
      3. Step 3: 133 inch. lbs. (15 Nm).

    4. Install or connect the following:

      Power steering pump Alternator bracket bolt near the thermostat housing Wiring harness to the lower manifold components, including the injector, EGR valve and ECT sensor Air conditioning compressor bracket-to-the lower intake manifold pencil braces
    5. Install transmission oil dipstick tube, if necessary.

      Fuel supply and return lines to the rear of the lower intake
    6. Temporarily reattach the negative battery cable, then pressurize the fuel system (by cycling the ignition without starting the engine) and check for leaks.
    7. Disconnect the negative battery cable.
    8. Install or connect the following:

      Heater hose to the lower intake Upper radiator hose to the thermostat housing Distributor assembly and engage the wiring Ignition coil Connect vacuum hoses to the upper and lower intake manifold. New upper intake manifold gasket, making sure the green sealing lines are facing upward Upper intake manifold Manifold retainers. Tighten them to 88 inch lbs. (10 Nm) using two passes. Purge solenoid and bracket Brake booster vacuum hose at the upper intake manifold PCV hose to the rear of the upper intake manifold Vacuum hoses to both the front and rear of the manifold assembly Throttle body Throttle linkage to the upper intake Wiring to the upper intake components including the TP sensor, IAC motor, MAP sensor and the fuel meter Engine cover Air intake assembly
    9. Connect negative battery cable.
    10. Refill the engine cooling system.
    11. Start the engine and check for leaks.

    Aug 26, 2010 | 1996 Chevrolet Astro

    1 Answer

    Intake manifold gasket / replace


    3.8L Engine

    NOTE The 3.8L (VIN K) non-supercharged engine uses a two-piece intake manifold consisting of an upper air plenum which mounts the throttle body and a lower intake manifold assembly which houses the fuel injectors. The 3.8L (VIN 1) supercharged engine uses a similar lower intake manifold. The supercharger serves as the upper manifold.
    Lower Manifold

    NOTE Two bolts which fasten the lower intake manifold to the cylinder head are accessible only after the upper intake manifold is removed. These bolts are located in the right front and left rear corners of the lower intake manifold. Remove the upper intake manifold to service the lower intake.
    The 3.8L (VIN 1) supercharged engine uses a manifold similar to the 3.8L (VIN K), but the supercharger serves as the upper manifold.
    1. Disconnect the negative battery cable.
    2. On 3.8L (VIN 1) engines, remove the supercharger assembly. Please see the procedure in this section.
    3. Remove the upper intake manifold using the procedure above.
    4. Remove the EGR outlet pipe from the intake manifold.
    5. Detach the engine coolant temperature sensor wiring harness from the sensor.
    6. Remove the lower intake manifold bolts and carefully lift off the manifold.

    To install:


    0900c15280269f1b.jpg enlarge_icon.gifenlarge_tooltip.gif Fig. Lower intake manifold bolt torque sequence-3.8L (VIN K) engine
    1. Clean all parts well with degreaser, especially the gasket seal surfaces on the upper and lower manifold pieces and between the lower manifold and the cylinder heads..
    2. Install new gaskets to the cylinder heads and new seals to the engine block. Carefully lower the manifold into place. Apply thread-locking compound to the bolt threads. Make sure to install the two hidden bolts in the lower intake manifold. Hand start all bolts, then torque evenly to 11 ft. lbs. (15 Nm). Follow the toque sequence, starting in the center, then working outwards in a circle.
    3. Install the remaining components in the reverse order of the removal process.

    Upper Intake Manifold (Plenum)
    1. Disconnect the negative battery cable.
    2. On 3.8L (VIN 1) engines, remove the supercharger assembly. Please see the procedure in this section.
    3. Tag for identification, then remove the right side spark plug wires.
    4. Disconnect the ignition wires from the fuel rail.
    5. Remove the fuel rail. Please see Section 5.
    6. Remove the cable bracket from the intake manifold.
    7. Remove the throttle body.


    NOTE Two bolts which fasten the lower intake manifold to the cylinder head are accessible are accessible only after the upper intake manifold is removed. These bolts are located in the right front and left rear corners of the lower intake manifold.
    1. Remove the upper intake manifold bolts and carefully lift the upper intake manifold from the engine.



    0900c15280269f1c.jpg enlarge_icon.gifenlarge_tooltip.gif Fig. Upper intake manifold and bolt torque sequence-3.8L (VIN K) engine
    To install:
    1. Clean all parts well with degreaser, especially the gasket seal surfaces on the upper and lower manifold pieces.
    2. Install new gaskets to the cylinder heads and new seals to the engine block. Carefully lower the manifold into place. Make sure to install the two hidden bolts in the lower intake manifold. Hand start all bolts, then torque evenly to 89 inch lbs. (10 Nm). Follow the torque sequence, starting in the center, then working outwards in a circle.
    3. Install the remaining components in the reverse order of the removal process.

    Sep 11, 2009 | 1999 Buick Regal

    1 Answer

    Blown headgasket


    Remove valve covers, drain radiator. remove hoses& linkage, distributor,intake manifold, loosen rockers and remove pushrods. disconnect exhaust pipes (dont worry too much if a stud breaks, you can replace them once out of car.) remove exhaust manifolds, remove head bolts. take heads off. clean off all surfaces and don't get any debris in engine. Get a manual if this is scary...Replace in reverse order. Check heads for cracks between valves, head torque is 65lbs, intake is anything around 30. Mark distributor so you can put it back in exactly like it came out...once nearly in, they usually stop. keep light hand pressure on it and turn engine by hand & it will drop the rest of the way in. tighten rockers till you can just spin the pushrod Move engine position to do any that have spring tension. adjust lash running by loosening till they clatter, turning till no noise and 1/2 turn further. When adjusting, oil will go everywhere so do it somewhere you can make a mess.

    May 23, 2009 | 1983 Chevrolet El Camino

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