How JustAnswer Works:

  • Ask an Expert
    Experts are full of valuable knowledge and are ready to help with any question. Credentials confirmed by a Fortune 500 verification firm.
  • Get a Professional Answer
    Via email, text message, or notification as you wait on our site.
    Ask follow up questions if you need to.
  • 100% Satisfaction Guarantee
    Rate the answer you receive.

Ask John Hicks Your Own Question

John Hicks
John Hicks, Technician
Category: Car
Satisfied Customers: 215
Experience:  I have been working on cars since I was 7. Currently self employed doing mobile auto repair.
5769668
Type Your Car Question Here...
John Hicks is online now
A new question is answered every 9 seconds

How do you change an intake gasket on a 97 Chevy Malibu

Resolved Question:

How do you change an intake gasket on a 97 Chevy Malibu?
Submitted: 5 years ago.
Category: Car
Expert:  John Hicks replied 5 years ago.
3.1L Engine

 

NOTE

The 3.1L engine is equipped with upper and lower intake manifolds. The upper intake manifold is also known as the intake manifold plenum.

 

CAUTION

The fuel system is under pressure and must be properly relieved before disconnecting the fuel lines. Failure to properly relieve the fuel system pressure can lead to personal injury and component damage.

  1. Relieve the fuel system pressure.

  2. Disconnect the negative battery cable.

  3. Remove the top half of the air cleaner assembly and throttle body duct.

  4. Drain and recycle the engine coolant.

  5. Disconnect the EGR pipe from exhaust manifold.

  6. Remove the serpentine belt.

  7. Remove the brake vacuum pipe at the intake plenum.

  8. Disconnect the control cables from the throttle body and intake plenum mounting bracket.

  9. Remove the power steering lines at the alternator bracket.

  10. Remove the alternator.

  11. Label and disconnect the ignition wires from the spark plugs and wire retainers on the intake plenum.

  12. Remove the ignition assembly and the EVAP canister purge solenoid together.

Exploded view of the upper and lower intake manifold and fasteners

Exploded view of the upper and lower intake manifold and fasteners

Click to Enlarge
  1. Detach the upper engine wiring harness connectors from the following components:

    • Throttle Position (TP) sensor

    • Idle Air Control (IAC) valve

    • Fuel injectors

    • Engine Coolant Temperature (ECT) sensor

    • Manifold Absolute Pressure (MAP) sensor

    • Camshaft Position (CMP) sensor

  2. Tag and disconnect the vacuum lines from the following components:

    • Vacuum modulator

    • Fuel pressure regulator

    • PCV valve

  3. Disconnect the MAP sensor from the upper intake manifold.

  4. Remove the upper intake plenum mounting bolts and lift off the plenum.

  5. Disconnect the fuel lines from the fuel rail and bracket.

  6. Install a suitable engine support fixture tool.

  7. Remove the right side engine mount.

  8. Remove the power steering mounting bolts and support the pump out of the way without disconnecting the power steering lines.

  9. Disconnect the coolant inlet pipe from the outlet housing.

  10. Remove the coolant bypass hose from the water pump and the cylinder head.

  11. Disconnect the upper radiator hose from the thermostat housing.

  12. Remove the thermostat housing.

  13. Remove both rocker arm covers.

  14. Remove the lower intake manifold bolts. Make sure the washers on the four center bolts are installed in their original locations.

 

NOTE

When removing the valve train components they should be kept in order for installation the original locations.

  1. Remove the rocker arm retaining nuts or bolts and extract the rocker arms and pushrods.

  2. Remove the intake manifold from the engine. Remove and discard the gasket.

  3. Using a suitable scraper, clean gasket material from all mating surfaces. Remove all excess RTV sealant from front and rear ridges of cylinder block.

To install:

  1. Place a 0.12 inch (3mm) bead of RTV, on each ridge, where the front and rear of the intake manifold contact the block.

  2. Using a new gasket, place the intake manifold on the engine.

  3. Install the pushrods in their original locations. Coat the pushrods with prelube.

 

NOTE

The intake pushrods are marked yellow (5 3/4 inch long) and the exhaust are green (6 inches long). Make sure the pushrods are properly seated in the valve lifters and rocker arms.

  1. Position the rocker arms in their original locations and tighten to the proper specifications.

  2. Install lower the intake manifold attaching bolts. Apply sealant or equivalent thread locking compound to the threads of bolts. Tighten the vertical bolts first, then the diagonal bolts to 115 inch lbs. (13 Nm).

  3. Install the front rocker arm cover.

  4. Install the thermostat housing.

  5. Connect the upper radiator hose to the thermostat housing.

  6. Fasten the coolant inlet pipe to the thermostat housing.

  7. Connect the coolant bypass pipe at the water pump and cylinder head.

  8. Install the power steering pump in the mounting bracket.

  9. Loosely install the serpentine belt.

  10. Connect the right side engine mount.

  11. Remove the special engine support tool.

  12. Fasten the fuel lines to fuel rail and bracket.

  13. Install the upper intake manifold and tighten the mounting bolts to 18 ft. lbs. (25 Nm).

  14. Install the MAP sensor.

  15. Connect the upper engine wiring harness connectors to the related components removed earlier.

  16. Connect the vacuum lines to the PCV, vacuum modulator and fuel pressure regulator.

  17. Install the EVAP canister purge solenoid and ignition assembly.

  18. Install the alternator assembly.

  19. Connect the power steering line to the alternator bracket.

  20. Install the serpentine belt.

  21. Connect the spark plug wires to the spark plugs and intake plenum wire retainer.

  22. Install the EGR pipe to the exhaust manifold.

  23. Attach the control cables to the throttle body lever and upper intake plenum mounting bracket.

  24. Install air intake assembly and top half of the air cleaner assembly.

  25. Install the brake vacuum pipe.

  26. Fill the cooling system.

  27. Connect the negative battery cable, then start the vehicle and verify that there are no leaks.

John Hicks, Technician
Category: Car
Satisfied Customers: 215
Experience: I have been working on cars since I was 7. Currently self employed doing mobile auto repair.
John Hicks and 10 other Car Specialists are ready to help you

JustAnswer in the News:

 
 
 
Ask-a-doc Web sites: If you've got a quick question, you can try to get an answer from sites that say they have various specialists on hand to give quick answers... Justanswer.com.
JustAnswer.com...has seen a spike since October in legal questions from readers about layoffs, unemployment and severance.
Web sites like justanswer.com/legal
...leave nothing to chance.
Traffic on JustAnswer rose 14 percent...and had nearly 400,000 page views in 30 days...inquiries related to stress, high blood pressure, drinking and heart pain jumped 33 percent.
Tory Johnson, GMA Workplace Contributor, discusses work-from-home jobs, such as JustAnswer in which verified Experts answer people’s questions.
I will tell you that...the things you have to go through to be an Expert are quite rigorous.
 
 
 

What Customers are Saying:

 
 
 
  • I would (and have) recommend your site to others I was quite satisfied with the quality of the information received, the professional with whom I interacted, and the quick response time. Thanks, and be sure that I'll be back whenever I need a question answered in a hurry. Stephanie P Elm City, NC
< Last | Next >
  • I would (and have) recommend your site to others I was quite satisfied with the quality of the information received, the professional with whom I interacted, and the quick response time. Thanks, and be sure that I'll be back whenever I need a question answered in a hurry. Stephanie P Elm City, NC
  • used your service this weekend with "Trecers" help. thank you ,thank you, thank you. replaced an A/C fan motor. Local Auto Zone had part. $15.00 "tracer" fee and $40.00 for parts, I saved several hundreds of dollers at a shop. i will recommend you and use you in the future. David L. Richmond, TX
  • 9 dollars, 2 hours of my time, and I drove away. Your diagnosis was right on the mark. Thank you so much. Phil Marysville, CA
  • Lurch. Thank you very much. I had real doubts about this website but your promptness of response, quick followup and to the point answer with picture was incredible. Charles Walnut Creek, CA
  • As a single woman, I really appreciate an excellent and affordable opinion.
    Thank you Geordie, I will not hesitate to contact justanswer in the future!
    Sue Charleston, WV
  • Another great insight to what may be the problem. I will have my mechanic take a look at it tomorrow. Thanks again, Frank...you do indeed know your stuff. Jim Castleberry, FL
  • Excellent reply, and also very quick. Really sounds like the Expert knows what he is talking about. I will be back to use your service when I need more help with my RV. Dutch USA
 
 
 

Meet The Experts:

 
 
 
  • Chris (aka-Moose)

    Technician

    Satisfied Customers:

    846
    16 years of experience
< Last | Next >
  • http://ww2.justanswer.com/uploads/MU/muddyford/2012-6-13_1204_1.64x64.png Chris (aka-Moose)'s Avatar

    Chris (aka-Moose)

    Technician

    Satisfied Customers:

    846
    16 years of experience
  • http://ww2.justanswer.com/uploads/TE/TedG/2012-6-15_14759_avaLarge.64x64.jpg Ted G.'s Avatar

    Ted G.

    ASE Certified Technician

    Satisfied Customers:

    1596
    20 years auto repair experience, ASE Master Tech, Mechanical Failure consultant, Expert Witness
  • http://ww2.justanswer.com/uploads/joecamel90/2008-11-13_03615_head_shot.jpg George H.'s Avatar

    George H.

    ASE Certified Technician

    Satisfied Customers:

    1311
    ASE Master Tech 15+ yrs, AAS Automotive Technology, Factory trained Asian specialist
  • http://ww2.justanswer.com/uploads/AM/amedee/2013-10-24_23656_Amedee1.64x64.jpg Amedee's Avatar

    Amedee

    ASE Master Tech

    Satisfied Customers:

    2367
    ASE Master Tech advanced level specialist
  • http://ww2.justanswer.com/uploads/SU/supermechanic/2013-8-23_03546_500.64x64.jpg Jerry's Avatar

    Jerry

    Master Mechanic

    Satisfied Customers:

    1906
    ASE master, 30+ years. All makes and models. Trouble shooter, shop forman, service manager
  • http://ww2.justanswer.com/uploads/CR/crzydrvr00/2013-11-3_12123_246347.64x64.jpg Richard's Avatar

    Richard

    ASE Certified Technician

    Satisfied Customers:

    942
    12 years Ford Lincoln/Mercury Jaguar dealership as a technician and shop foreman reparing all makes
  • http://ww2.justanswer.com/uploads/ST/Steve7654/2012-6-5_215929_japic800x660.64x64.jpg Steve's Avatar

    Steve

    Auto Service Technician

    Satisfied Customers:

    1980
    25+ yrs experience as a professional working technician; ASE L1 master technician