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Super Mechanic
Super Mechanic, Master technician
Category: Chevy
Satisfied Customers: 17218
Experience:  29 yrs. exp., ASE master, cert. in G.M. electrical, a/c, susspension, brakes, electronic steering
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how to replace intake gaskets on 4.3 chevy s10 1996 model

Resolved Question:

how to replace intake gaskets on 4.3 chevy s10 1996 model
Submitted: 8 years ago.
Category: Chevy
Expert:  Super Mechanic replied 8 years ago.

Hello and welcome to Just answer.com, Super mechanic here. About your vehicle.

 

Let me give you both the upper and lower intake instructions. Although you can sometimes take them both off together when you get the fuel lines out of your way and have the distributor out. On the distributor you will want to use a small wrench or a swivel socket, as it is a tight spot in there.

 

Intake Manifold Replacement (Upper)

 

 

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REMOVE OR DISCONNECT

  1. Negative battery cable.
  2. Drain the engine coolant.
  3. Air cleaner inlet duct.
  4. Wiring harness connectors and brackets.
  5. Throttle linkage and bracket.
  6. Fuel lines and bracket at the rear of the lower intake manifold.
  7. Brake booster vacuum hose.
  8. Ignition coil.
  9. PCV pipe and vacuum hoses.
  10. Purge solenoid and bracket.
  11. Upper intake manifold bolts and manifold. Mark the location of the bolts for proper reassembly.

INSTALL OR CONNECT

  1. New upper manifold gasket with sealing lines facing up.
  2. Upper intake manifold. Do not pinch the injector wires between the upper and lower intake manifolds.
  3. Upper intake manifold bolts and studs noting the marks made during disassembly. Tighten the bolts in two steps:
    1. Tighten to 5 Nm (44 in lbs) .
    2. Tighten to 10 Nm (89 in lbs) .
  1. Purge solenoid and bracket.
  2. PCV pipe and vacuum hoses.
  3. Ignition coil.
  4. Brake booster vacuum hose.
  5. Fuel lines and bracket at the rear of the lower intake manifold.
  6. Throttle linkage and bracket.
  7. Wiring harness connectors and brackets.
  8. Air cleaner inlet duct.
  9. Negative battery cable.
  10. Fill and recheck engine coolant level.
  11. Inspect for leaks:
    1. Turn the ignition switch to the "ON" position for 2 seconds.
    2. Turn the ignition switch to the "OFF" for 10 seconds.
    3. Turn the ignition switch to the "ON" position.
    4. Check for fuel leaks.

 

 

 

 

Intake Manifold Replacement (Lower)

 

 

graphic

 

graphic

 

 

graphic

 

 

graphic

 

 

REMOVE OR DISCONNECT

  1. Negative battery cable.
  2. Drain the cooling system.
  3. Air cleaner intake duct.
  4. Wiring harness connectors and brackets.
  5. Throttle linkage and bracket.
  6. Fuel lines and bracket at the rear of the lower intake manifold.
  7. Vacuum hoses to upper and lower intake manifolds.
  8. Distributor. Mark the housing and rotor positions for proper reassembly.
  9. Upper radiator hose at the thermostat housing.
  10. Heater hoses at the lower intake manifold.
  11. Wiring harness and brackets.
  12. Transmission oil level indicator and tube (automatic transmissions only).
  13. Air conditioning compressor and bracket.
  14. EGR tube, clamp, and bolt.
  15. Alternator bracket bolt next to the thermostat housing.
  16. Lower intake manifold bolts and manifold.
  17. Clean gasket surfaces, carbon buildup and deposits from EGR and exhaust passages. Also, scale and deposits from coolant passages.
  18. Inspect manifold for cracks, broken flanges and gasket surface damage.

INSTALL OR CONNECT

  1. Gaskets onto the cylinder head with the port blocking plates facing the rear of the engine and the "This Side Up" stamping facing up.
  2. Apply a 5 mm (1/4 inch) thick bead of Wacker T-330 RTV, GM P/N 12346192 to the front and rear sealing areas of the engine block and intake manifold. Extend the RTV bead 13 mm (0.499 inch) up the cylinder head in order to seal and retain the gaskets.
  3. Lower intake manifold to the engine and apply sealer to the lower intake manifold bolts.
  4. Install the lower intake manifold bolts. Tighten bolts in sequence and in three steps:
    1. First sequence to 3 Nm (27 in lbs) .
    2. Second sequence to 12 Nm (106 in lbs) .
    3. Final sequence to 15 Nm (11 ft lbs) .
  1. Alternator bracket bolt next to the thermostat housing.
  2. EGR tube, clamp, and bolt.
  3. Air conditioning compressor and bracket.
  4. Transmission oil level indicator and tube (automatic transmissions only).
  5. Wiring harness and brackets.
  6. Heater hoses at the lower intake manifold.
  7. Upper radiator hose at the thermostat housing.
  8. Distributor. Noting the housing and rotor positions as marked during disassembly.
  9. Vacuum hoses to upper and lower intake manifolds.
  10. Fuel lines and bracket at the rear of the lower intake manifold.
  11. Throttle linkage and bracket.
  12. Wiring harness connectors and brackets.
  13. Air cleaner intake duct.
  14. Fill and recheck the coolant level.
  15. Negative battery cable.
  16. Inspect for leaks:
    1. Turn the ignition switch to the "ON" position for 2 seconds.
    2. Turn the ignition switch to the "OFF" for 10 seconds.
    3. Turn the ignition switch to the "ON" position.
    4. Check for fuel leaks.

 

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