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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.
» Before You Start
» Intake Manifold (Upper)
» Intake Manifold (Lower)

Intake Manifold Replacement (Lower)


  1. Disconnect the negative battery cable.
  2. Remove the upper intake manifold.
  3. Drain the cooling system.
  4. Remove the upper radiator hose.
  5. Remove the generator.
  6. Remove the drive belt tensioner.
  1. Remove the EGR valve outlet pipe.
  1. Remove the lower intake manifold bolts.
  2. Remove the lower intake manifold.


CAUTION: In order to complete the installation, observe the following assembly tips:
  • Clean the cylinder block, heads and the intake manifold sealing surface of all oil with a suitable solvent.
  • Clean the intake manifold bolts and bolt holes of adhesive compound.
  • Apply thread locking compound GM P/N 12345739 or equivalent to the intake manifold bolt threads before assembly.
  • Install the lower intake manifold gasket.
  1. Install the lower intake manifold.
  2. Apply GM P/N 12345382 thread locker or equivalent on the bolt threads.

Lower Intake Tightening Sequence
  1. Install the lower intake manifold bolts including the two hidden bolts. Torque the bolts in sequence to 15 Nm (11 ft. lbs.).
  2. Connect the negative battery cable.
  3. Install the EGR valve outlet pipe.
  4. Install the drive belt tensioner.
  5. Install the generator.
  6. Install the upper radiator hose.
  7. Fill the cooling system.
  8. Install the upper intake manifold.
» Part 1       » Part 2       » Part 3

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

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