I have had a moderate oil leak for some time (around 1 QT a month) and know that some is from the distributor gasket that goes bad on these motors (1989 Trooper with 2.8 V6). I recently replaced my A/C compressor and while doing so, I found alot of build up behind it. After cleaning this off mildly, I got some small pieces of rubber that look like its the original rubber bead intake manifold gasket that I have heard frequently fail and leak. This is from the front bottom of the intake between the valve covers where it connects to the block. My question is this-how hard is it to replace the intake manifold gasket myself as a basic DIY? I have never dug into an engine besides replacing simple stuff like alternator and other pulley driven components. I do my own tune ups and basic stuff but this is a pretty big undertaking. I think if I end up doing this, I may want to do some more upgrades while I have it torn apart like the 4.3 TBI upgrade and have the intake machined for better air flow. What others would be recommended while the top of the engine is torn apart and remember my basic knowledge and only working out of a chiltons and haynes since I haven't been able to find a helms for the 89 trooper yet--their site keeps saying sold out. Thanks ahead of time for reading this long rambling post.

Not too bad, but certainly a big step up from an alternator.

Removing the manifold and replacing the gasket isn't the hard part--it's getting to it (removing the TBI) where you have to be concerned.

You'll need to keep track of all of those vacuum hoses, fuel lines and electrical connections. In addition to a new intake manifold gasket, you'll need a new gasket for the TB. You will definitely need a torque wrench.

I've pulled the intake manifold on a couple of engines, though not a GM 2.8L V6. If you don't already have a repair manual of some sort, now would be a good time to buy one.

I would agree with the previous poster to some extent. Removing and replacing the intake manifold is a little more involved than replacing an A/C compressor, but the concept is the same. Do things one step at a time - take your time - and try to document/remember as much as you can while you are disassambling.

Here's what I would suggest...find the Haynes manual for a 1992-1997 Rodeo, as the 3.1L in the Rodeo is the same 2.8L GM engine in your rig. When you start to work on the truck take plenty of pictures of the brackets and their locations, hoses, and anything else that you might remove (having a digital camera works well). Doing this has saved my @SS a couple of times when I first started working on my rig. Invest in a box of ziplock bags and put and screws that you remove from parts as you go in there, along with labeling the bag (i.e. all the manifold screws). You might want to tape the bag to the part just in case, like the bracket screws to the bracket. You can "borrow" a torque wrench from Discount Advanced Auto Zone Boys <img src="/forums/images/graemlins/smile.gif" alt="" /> for a small fee.

You can do it, it's not that hard, and the only way to learn is to get your hands dirty. Of course, this board is here to help when you get stuck.

i did this two times in one day (no fun) but one thing to remember is not to over-torque the intake. you can VERY easily strip the studs/bolts.

a lot of people who work on their 2.8/3.1's start out saying its a PITA to mess with (myself included) but after you have done the procedures once or twice, you realize it's really not bad at all. the TBI isn't difficult at all and the alternator is cake compared to other engines. <img src="/forums/images/graemlins/cheers.gif" alt="" />

Thanks for the quick replies. I am thinking I am gonna do it myself. I think I will also do the TBI swap and switch my valve covers at the same time and just replace all those gaskets. Big thanks for the idea of taking pics. I would have never thought of that. I have a digital camera and will take many every step. Now I just have to shop around for a machine shop and gasket set and I think I have a weekend project. Since my wife is a teacher, I will wait until school is out so I can take as long as I want working on it. <img src="/forums/images/graemlins/kewl.gif" alt="" />

post

sorry server crashed and i lost the pics

edit: found pics

If you are going to pull the valve covers it would be a good time to install 1.6 roller rocker arms. Do it all at one time and never look back.
The hardist part of the job will be cleaning the old gaskets off. might try Gunk and some Aluminum foil oven turkey cooking trays, soak parts over night.
Let us know how it turns out.

John in LV

I was curious what all is involved in the 1.6 roller rocker upgrade. I am most likely going to do this as soon as I get some time to, but I was wondering if it just involves the valve covers or if I have to rip into the intake manifold as well. If I have to take the manifold off, I would just assume take it and have it bored out and bolt the 4.3 TBI on. Didnt mean to hijack or nothing, just that Im thinking about doing the same thing at one point.

Dan

I have been told on chevys instead of using gaskets for the front and rear of the intake manifold use RTV I'm not sure if this is true for the 2.8 though Maybe someone else knows for sure <img src="/forums/images/graemlins/cheers.gif" alt="" />

RTV is the way to go!!! Just make sure to let it set up for a little while first, and get a little under the intake gasket where it sits on the galley end. NAPA intake gaskets will have tabs that allow for great placement of the gasket. I suggest using these for the replacement.