Question about 2000 Buick Regal

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Need to remove and replace the intake manifold gaskets on a 2000 Buick Regal GS, with 3.8 Ltr Supercharged engine. The engine is leaking coolant from below the intake manifold.

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  • honeymokey
    honeymokey May 11, 2010

    Be sure to get the intake checked at a machine shop for warpage.

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  • 158 Answers

It is a great deal of work. The molded gaskets breakdown with time. You'll want to change the two 90 degree elbows as well - they are available from a dealer for a reasonable price. Also, the blower gasket is likely shrunk up and /or blown out. And you might as well replace the valve cover gaskets too as they leak oil as they breakdown with heat and time.

I did all of this on mine. Even as a professional, it took me a good 6 hours.

Posted on Aug 11, 2010

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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

2 Answers

I have a 1997 buick lesabre w/ 24k


While there is a problem with the plastic Intake manifold, I would not worry too much about it. I was a buick tech, I own an 01, and at 95K I replaced my intake gaskets, but only because I still had an extended warranty. My manifold was fine.

The gaskets had begun to leak just a little, and I probably could have just used a good sealer, but since I had the warranty and managed a repair shop, I had it done. You will know when it is time, You will either smell the coolant, or your coolant light will come on. Just because it is a common problem, does not mean it will be your problem.

Sep 05, 2009 | 1997 Buick LeSabre

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