Leaking intake gasket

[beandip_62]

I have a leak in my lower intake gasket (leaking externally) and the first estimate I got, they told me $680 to fix that along with 2 other gaskets that would need replaced in the process and a radiator flush n fill.

I tried putting some radiator stop leak in, but my low coolant light just came back on.

Anyone know of somewhere I can get this done fairly cheap in the Central Ohio area (east of C-bus)? Or would it be insanely hard to do myself? Any links to a walkthrough of how to do this with pictures?

[mikem220153]

$680.00 is about average for this job. The intake manifold is a 2 piece affair consisting of and upper manifold, called the plenum, and the lower intake manifold. It is done this way, because of the way our fuel injectors are connected to the manifold.

The lower gaskets are where your leaks are. The other 2 gaskets are the ones for the upper plenum.

If your mechanically inclined this job will take you a good day to a day and a half. Get a Chilton's manual for your car. It will give you a detailed description on what to do. It is pretty labor intensive.

Stop leak won't do you any good. If the gasket is leaking externally, your running on borrowed time before it starts leaking internally, then you will have a lot more problems. Don't put this repair off.

Check out the 3100 engine section of this site. There is a lot of discussion about it there. The 3100 and the 3400 engines use the same procedures even though the parts are a little different.

[DangerMouse]

GM Revised the gasket installation proceedures, and the gasket itself last May.

[ddtherrien]

Does anyone have the revised installation procedure? I have the manifold off and ready for re-installation. A detailed and improved procedure would be very helpful....

[DangerMouse]

Revised LIM Gasket TSB from GM as of March, 2003. (http://152.122.48.12/prepos/files/Artemis/Public/TSBs/2003/SB-10001282-8175.pdf)

Tells you which bolts to install first I believe, along w/ proper torque settings, etc. You need to be careful not to crush the LIM Gasket when installing.

[ddtherrien]

Thank you very much for this detail.

My GA is a 97 which is not specifically listed on the TSB. It references the 99-03 model years. Do you know if the same TSB applies for the 97?

Also, the "trough" area on the LIM is sealed using RTV supplied with the kit. My intent is to put a sufficient bead down the center of the mating surface with extra volume at the corners.

Lastly, would it be adviseable to re-torque the head bolts prior to reinstalling the LIM? Do you have that torque value and sequence. Perhaps I need to invest in a manual.

[DangerMouse]

I believe they're different, as that TSB applies only to the '99+ GAs/Aleros w/ the 3.4 liter engine.