Intake manifold gasket replacement on 1992 "Z" vin

Radiator, thermostat, water pump, antifreeze, etc.
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JTalley
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Intake manifold gasket replacement on 1992 "Z" vin

Post by JTalley »

Unfortunately, it's time to replace it. I finally figured out where that water was coming from, and it turns out that was it. I need to know what the bolts should be torqued to, first of all. Also, I heard they have a sealant that you have to put on the bolts when you put them in so that they don't loosen up over time. Any truth to that? If so, what do I use? How do I mark the distributer before I remove it? I noticed on the new gaskets that something called the "rear port" seems to be blocked, and apparently that has something to do with rear heat? I don't have rear heat, so is that a problem?

Basically, I need all the information I can get.
Jake

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Ed- 1992 Astro, RWD, 4.3l V6 (purchased Feb. 2011)
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Re: Intake manifold gasket replacement on 1992 "Z" vin

Post by doyoulikeithere »

Hi JT.
The blocked rear water port is the way it should be, has nothing to do with a rear heater. Dont unblock it.
You could use lock-tite to keep the head bolts from backing off, but more importantly, use a SMALL amount of RTV Sealant around the water ports on the gaskets so water wont leak out after its installed.
I am not at home so dont have the torque specs handy, maybe later if no-one else chimes in before that.

I would rotate the engine by hand, keeping an eye on the distributer with the cap off. when it gets near to the #1 wirs, watch the crank pulley till it hits the TDC mark.
Then scribe a mark that will be able to line up the Distrib shaft with the manifold hole.
To re-install, if you havent turned the engine, good, otherwise re-line up #1 TDC. Drop the Dist into the hole when its at #1 TDC, and mesh the gears so that the rotor point back to the #1 wire again, then re-align the mark you scribed and you should be good to go, or at least right back where it started. Time it with a light afterwards to be certain its good.

Good Luck Bud.
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Re: Intake manifold gasket replacement on 1992 "Z" vin

Post by JTalley »

doyoulikeithere wrote:Good Luck Bud.
Thanks. I'll need it. [-o<
doyoulikeithere wrote:You could use lock-tite to keep the head bolts from backing off...
Could that cause problems if I ever need to take it off in the future?
Jake

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Ed- 1992 Astro, RWD, 4.3l V6 (purchased Feb. 2011)
FlowTech Red Hots glasspack exhaust (finally got it put on there!)
Old rides (earlier to later)
2004 Honda 250 Rebel (my dad's bike, he let me use it)
Neko- 1991 S10 Blazer, 4x4, 4-door (SOLD Feb. 2011)
Custom (aka failed) diy paint job- red with black stripe
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Re: Intake manifold gasket replacement on 1992 "Z" vin

Post by doyoulikeithere »

JTalley wrote:Could that cause problems if I ever need to take it off in the future?
No.
Unless you are a really wimpy little girl who wont be able to undu them later.
2021 Yamaha Tenere 700 - Blue.
2016 Yamaha XSR900 - Silver.
1990 Astro - AWD - Brown.
1987 Astro - With 5 Speed & 4wd - Silver & Blue.

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Re: Intake manifold gasket replacement on 1992 "Z" vin

Post by brokenwrench »

red loctite is for ever, blue is a little easier to get off, there are several much cheaper knock offs, a regular sized bottle of loctite is $40 here. the

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Re: Intake manifold gasket replacement on 1992 "Z" vin

Post by 97CargoCrawler »

You're supposed to use a NON-HARDENING sealant on the bolts. The gasket kit mentions a certain type but I forget what it was and I can't seem to find the paper. I used anti-sieze lube. Last thing I need is a stripped out head or a broken bolt next time I need to remove it.

The torque is different depending on the year of the vehicle. Mine was 11ft-lbs for the manifold to head bolts. The older years are higher. Be sure to torque them in three steps and in the proper pattern.

If you get a Fel-Pro kit it comes with pretty decent instructions. Don't apply more than 1/4" of sealant on the front and rear of the head to manifold mating surfaces.....they don't give you any extra in the tube provided with the kit....I found out the hard way.

Good Luck! It's a pretty easy job. The hard part is cleaning all the crap off the top of the engine and mating surfaces.
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Re: Intake manifold gasket replacement on 1992 "Z" vin

Post by JTalley »

I have everything taken apart... When I opened it up, I found everything inside to be completely black. The underside of my intake manifold is covered in rust, also.

How do I clean everything?
Jake

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Ed- 1992 Astro, RWD, 4.3l V6 (purchased Feb. 2011)
FlowTech Red Hots glasspack exhaust (finally got it put on there!)
Old rides (earlier to later)
2004 Honda 250 Rebel (my dad's bike, he let me use it)
Neko- 1991 S10 Blazer, 4x4, 4-door (SOLD Feb. 2011)
Custom (aka failed) diy paint job- red with black stripe
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Re: Intake manifold gasket replacement on 1992 "Z" vin

Post by doyoulikeithere »

I wouldn't go too nuts cleaning it to shine.
It will be dirty again soon, and you cant see it anyways.
Just wipe off any excess crud, clean the gasket surfaces, and re-install the manifold.
2021 Yamaha Tenere 700 - Blue.
2016 Yamaha XSR900 - Silver.
1990 Astro - AWD - Brown.
1987 Astro - With 5 Speed & 4wd - Silver & Blue.
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Re: Intake manifold gasket replacement on 1992 "Z" vin

Post by JTalley »

Some people say to clean the gasket surfaces you use a putty knife. I don't want to score that, so how do I do it?

Also, the old gasket is partially stuck to the motor. How can I get that off easier? When I tried yanking it off by hand it broke... Several times.
Jake

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Ed- 1992 Astro, RWD, 4.3l V6 (purchased Feb. 2011)
FlowTech Red Hots glasspack exhaust (finally got it put on there!)
Old rides (earlier to later)
2004 Honda 250 Rebel (my dad's bike, he let me use it)
Neko- 1991 S10 Blazer, 4x4, 4-door (SOLD Feb. 2011)
Custom (aka failed) diy paint job- red with black stripe
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Re: Intake manifold gasket replacement on 1992 "Z" vin

Post by doyoulikeithere »

I used a putty knife to remove all the old gaskets.
On the steel heads, the knife would have a hard time damaging the steel.
On the Aluminum Manifold, use a putty knife but be very careful to use the flat edge, as the corners can dig into the aluminum.
Just be careful and your fine.
2021 Yamaha Tenere 700 - Blue.
2016 Yamaha XSR900 - Silver.
1990 Astro - AWD - Brown.
1987 Astro - With 5 Speed & 4wd - Silver & Blue.
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Re: Intake manifold gasket replacement on 1992 "Z" vin

Post by JTalley »

I feel like a pathetic excuse for a mechanic right now. The van has been tore down for a WEEK and I still haven't got it all cleaned off. Apparently putty knives are some kind of rare artifact because nobody has one. Well, they do, but nobody knows where they put them. I can't buy one- the only thing in my wallet is lint because it's been almost two weeks since payday and my money completely re-defined the meaning of the word "disperse."
:cry:
Jake

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Ed- 1992 Astro, RWD, 4.3l V6 (purchased Feb. 2011)
FlowTech Red Hots glasspack exhaust (finally got it put on there!)
Old rides (earlier to later)
2004 Honda 250 Rebel (my dad's bike, he let me use it)
Neko- 1991 S10 Blazer, 4x4, 4-door (SOLD Feb. 2011)
Custom (aka failed) diy paint job- red with black stripe
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Re: Intake manifold gasket replacement on 1992 "Z" vin

Post by doyoulikeithere »

A steel ruler from the school will work in a pinch.
2021 Yamaha Tenere 700 - Blue.
2016 Yamaha XSR900 - Silver.
1990 Astro - AWD - Brown.
1987 Astro - With 5 Speed & 4wd - Silver & Blue.

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Re: Intake manifold gasket replacement on 1992 "Z" vin

Post by 97CargoCrawler »

Ask any old dude if he has a putty knife you can borrow and he'll most likely produce and assortment to choose from.

Be sure to cover the exposed engine internals. I had mine covered with a rag when I did this a few weeks back and it caught 90% crap I chiseled off. The rest needed to be sucked out with a shop vac.

This will make some folks cringe but I used a sanding disk on the end of a drill to clean the surfaces. They were so corroded and pitted I figured it wouldn't matter much, and it didn't. Obviously you want to use super fine grit. I bought my discs at Harbor freight for like $5 a package. Worked like a charm, left the head and manifold shiny and looked machined. The gasket is about 1/8" thick so any slight deviations in the machined surface aren't gonna matter. Be sure to wear a particulate filter mask on your face if you go this route.
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Re: Intake manifold gasket replacement on 1992 "Z" vin

Post by JTalley »

I'm upset. All that work... I started it up yesterday and water just POURED out of the manifold, all over the top of the engine, steady drip out of the exhaust, sputtering... I think I'll just pay a professional to redo it again.
Jake

Image
Ed- 1992 Astro, RWD, 4.3l V6 (purchased Feb. 2011)
FlowTech Red Hots glasspack exhaust (finally got it put on there!)
Old rides (earlier to later)
2004 Honda 250 Rebel (my dad's bike, he let me use it)
Neko- 1991 S10 Blazer, 4x4, 4-door (SOLD Feb. 2011)
Custom (aka failed) diy paint job- red with black stripe
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Re: Intake manifold gasket replacement on 1992 "Z" vin

Post by doyoulikeithere »

JT, Sorry to hear this.
Its a pretty straightforward job, Not sure why it would leak so bad, unless you left a big chunk of old gasket attached.
Was there any coolant in it, or just plain water?
Have you figured out where exactly the leak is?
Chances are you will need to flush the liquid out of your oil now.
DO NOT run it, until you fix that.

read this thread.......
viewtopic.php?f=51&t=7702
2021 Yamaha Tenere 700 - Blue.
2016 Yamaha XSR900 - Silver.
1990 Astro - AWD - Brown.
1987 Astro - With 5 Speed & 4wd - Silver & Blue.
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