Intake manifold gasket replacement on 1992 "Z" vin

[97CargoCrawler]

Bummer. Don't be discouraged, these things happen. Every mechanic has several stories just like this. It should take you 1/2 as much time to do it again now that you are familiar with the process.

Did you torque the manifold to head bolts in the right pattern to the correct ft-lbs? How pitted was the head and manifold?

Definitely do not even start the engine if there's water in the oil. It will hydrolock and that will be the end of it.

You can recover from this, I did just a few weeks ago. Requires a little cleaning and a lot of oil changes. Check out my thread:

viewtopic.php?f=51&t=7702

EDIT: HAHA! I guess my disaster was already referenced. My engine runs PERFECTLY now. Buy the cheapest oil, filters and best flush you can find after you fix the gasket to clean out the engine. It'll be fine.

Give it another shot!

[JTalley]

Surprisingly, it wasn't pitted very bad. I only found one or two spots, and they were barely noticable. I think I just didn't get them torqued properly. No torque wrench I could get would fit in there, so I had to guess, and I suppose I guessed wrong. I tightened them more afterwards, but the damage was apparently already done, and it still leaked.

[1Gary]

I have crow's feet to get into tight spaces like that.No Jake,you can't guess on those torque values.And you should do them in steps to get to the proper torque.

[doyoulikeithere]

Yes Gary, Crow's Feet are the ticket on those bolts up beside the TBI riser.
I doubt you have any Jake, but see if you can find a loaner, it will help a lot.
FYI, I guessed on 1 bolt of mine for the same reason, but I guessed right I guess, cuz its still going strong.

[97CargoCrawler]

I didn't have any problems getting in there on mine. I was using a 2' wrench with some socket extensions. It's difficult on your body trying to get in there though. I had to remove my seats.

Be double sure of the torque specs for your year van. I know older vans have a higher torque rating for the manifold.

[doyoulikeithere]

I didn't have any problems getting in there on mine.

You run a Vortec manifold don't you 97CC? You wont have the same issue on that manifold.
I had my engine in the basement on an engine stand, and I could not get any torque wrench to fit in to where the 2 bolts right beside & under the TBI are.
Anyways a Crow's Foot Tool is the best solution, for those 2 bolts on a TBI manifold. (I guessed on those 2 only)

[97CargoCrawler]

Yes, that is correct. I am not familiar with the older style. Not sure a crows foot is the best solution if you actually care about the proper toque setting being that they are offset and act as another lever arm. But at least it might fall in the ballpark. I bet GM has a special service tool just for that!

Is it possible to remove the TBI for better access?

[JTalley]

I had the TBI off, it was just the part that goes up where it bolts on was in the way. Today I think I'll go to O'Reilly's and rent a good torque wrench and see about crow's feet.
Since the new gasket leaked when I had it torqued improperly, will I be able to use it or will I have to buy another?

[1Gary]

My two cents worth is to get a new gasket.

[doyoulikeithere]

dont waste your time with the old 'wetted' & 'Squished' gaskets.

The actual TBI is not the problem, it is the riser for it (part of the manifold casting).

The extra distance of the crows foot is not much if you install it in a position that makes your leverage longer, but if you install it 90 degrees to that so it sits to one side the distance does not change much at all. While not perfect, its close enough, considering that it will be closer than my guess.

[97CargoCrawler]

Updates?

[JTalley]

Unexpected stuff came up and I don't have much cash. All I have is a $10 bill, and I found that in my wallet with no idea where it came from. Someone owes me some money, though, so when I get that I can get the new gasket and see about a crow's foot.

I really miss the van, and I hate how long this is taking.

[JTalley]

IT'S FINALLY FIXED!!!!!!!!!!

After a ton of (extra) work, we got it fixed. I had to get a new heater hose connector and put that on, and I broke a rubber elbow for a vacuum line (which I don't have fixed yet), but it runs now, and I drove it to school today. I feel like a million bucks right now. I just hope it doesn't leak somewhere I haven't seen yet...

[astroturf]

Congrats

[97CargoCrawler]

That's AWESOME dude!

How did you flush the coolant/oil crud from the engine internals?