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DIY: Intake Manifold Gasket: GM 3.8 Liter V-6

If you have a General Motors vehicle with a V-6 engine in it, this is something you will want to know how to do and save yourself some major bucks.
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» Before You Start
» Intake Manifold (Upper)
» Intake Manifold (Lower)


What you will need:

  1. Ratchet wrench set with deep sockets and universal joint
  2. Screwdrivers
  3. Six point combination wrenches
  4. Torque wrench, foot pounds and inch pounds
  5. Hammer
  6. Pry bar
  7. Gasket scrapper and spray gasket remover.
  8. Thermostat and gasket (recommended)
  9. Upper and lower intake manifold gaskets
  10. GM RTV sealer P/N 1052917 or equivalent
  11. Penetrating lubricant

Before You Start:

  • Follow these instructions carefully. Read and be sure you understand them before you begin.
  • Gather together all of your tools and supplies before you begin. Allow plenty of time to do the job so you don't have to hurry.
  • Remember that these are general instructions. For more detailed instructions pertaining to your specific vehicle, consult an appropriate repair manual.
  • Safety is important whenever you're working around machinery. Beware of hot objects, sharp instruments and hazardous materials.
  • Don't substitute tools unless you're sure you won't compromise either your safety or the performance of your vehicle.
  • Never work on a vehicle that is only supported by a jack. Use jack stands to support the vehicle while you work. Work on a solid, level surface. Never jack a car up on dirt or grass.
  • Carefully note what vacuum lines get connected to where. Use masking tape and a marking pen to number lines and fittings. Line one to fitting one; line two to fitting two and so forth. Or, alternatively, map out the vacuum lines on a piece of paper or get a vacuum line schematic.

Why Replace Your Intake Manifold Gaskets?

Intake manifold gaskets leaking coolant is a fairly common problem on General Motors V-6 engines. At, around, 80,000 miles it is something you should look for when doing your regular under hood maintenance. It is not a very difficult job; it's just a lot of work. While these instructions are for the GM 3.8 liter V-6, they will generally apply to any GM V-6 with a 2-piece intake manifold and 3.1 liter engines. Just take your time, use a little common sense and you should have no problems replacing them yourself.

General information

The intake manifold is a two-piece design. The upper portion is made from a composite material and the lower portion is cast aluminum. The throttle body attaches to the upper manifold.

The lower manifold has an Exhaust Gas Recirculation (EGR) port cast into the manifold for mixture. The EGR valve bolts into the lower intake manifold.

The Central Sequential Multi-Port Fuel injection (SFI) system uses multiple injectors to meter and distribute fuel to each engine cylinder. A bracket bolted to the lower intake manifold retains the Central SFI.

The fuel meter body also houses the pressure regulator. Metal inlet and outlet fuel lines and nylon delivery tubes connect to the Central SFI unit. The delivery tubes independently distribute fuel to each cylinder through nozzles located at the port entrance of each manifold runner where the fuel is atomized.

Okay, so let's get started!!

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» Part 1       » Part 2       » Part 3

Additional Information provided courtesy of
ALLDATAdiy.com and Warranty Direct
© 2000-2007 Vincent T. Ciulla

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