Other maintenance to do when changing intake manifold gasket

Other maintenance to do when changing intake manifold gasket

Postby SportsBoy [OP] » December 28th 2017, 5:10pm

Hey all, 1997 AWD Safari 122k here.
Got my oil analyzed by Blackstone and found there's coolant in the oil - 84297

I, like them, suspect intake manifold gasket is the problem - am going to try to pinpoint soon enough, but I'm kind of assuming it's that for now because of the frequency of the problem and because coolant appears to be dripping down the backside of the engine. Oil is not a milkshake, looks normal.

Been doing a bunch of research on how to do the job, and making a list of things to do along the way. I got the van with reasonably low mileage, but it seems like it's barely had any maintenance done in its 20 years.

This is what I'm thinking of doing while I'm in there - water pump, alternator, idler pulley, tensioner pulley, plugs and wires, cap and rotor, coil, fuel pump, and coolant flush all already done in the last 3,000 miles. Engine compression test this month had all cylinders holding 180lbs pressure.

Definitely doing:
Intake manifold gaskets and new bolts
Plenum gasket
Valve cover gaskets
Fuel spider for CSFI to MPFI switchover (includes fuel pressure regulator, which I definitely wanted to do)
Vacuum lines
PCV Valve
Thermostat (thinking about going to 180 degree)
Serpentine belt
Clean MAF sensor and throttle body and idle air control valve

Maybe doing:
Oil Cooler Delete
Coolant Temperature Sensor
Heater valve and heater bypass valve
Ignition control module
Head gaskets
Exhaust manifold gaskets

Probably not doing:
Efan
Transmission cooler
Crankshaft position sensor
New radiator hoses

My big questions are:
- For an MPFI spider, can I go with this (cheapest) or is ACDelco a must? http://bit.ly/2zHHan1
- Regarding the heater valve and heater bypass valve, I had heat in the back, but got rid of it - do I not need one of these now?
- Is there somewhere you can buy vacuum lines as a set? I've been having a hard time finding anything more than this http://amzn.to/2pPWVc0
- Should I do the head gasket while I'm in there? I'd really like to not have to open it up again in the next 5 years - looking at getting this set http://amzn.to/2lmgtzh. Also, should I get the cylilnder head bolt set if I do this?

Also, any thoughts on this list? Things that should be a higher priority or lower? I want to get this van in tip top shape and not have to worry (too much) about things going wrong on road trips.

Thanks so much for looking through all this! I'm new and am definitely open to advice and guidance - hoping anything stupid on here can be pointed out for me. This forum has been immensely helpful in researching all this stuff - hopefully someday I can contribute! :ty:
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Re: Other maintenance to do when changing intake manifold ga

Postby Toskavat » December 28th 2017, 5:22pm

Do a good inspection of the distributor, gear, play etc..
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Re: Other maintenance to do when changing intake manifold ga

Postby 1lowcab » December 28th 2017, 5:33pm

Just make sure you use the Felpro lower intake gasket with the metal insert, can't remember the part number off hand. They make both, a fiber/plastic one and a metal one...GET THE METAL ONE!!!! lol
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Re: Other maintenance to do when changing intake manifold ga

Postby MI_Ghost » December 28th 2017, 6:28pm

Do not worry about the head gaskets. You have good compression.
Spend the extra money for the Delco spider. ACDelco 217-3028 Fuel Injector
Go with the 4 port heater control valve. ACDelco 15-5557 Heater Control Valve
Replace the problem prone plastic distributor with a Skip White/ KMJ alloy distributor. JM6671BK/ARC 1326202

Make sure you clean the carbon out of the egr passage in the intake while you have it off
Dorman 47007 egr gasket

I just did all this on mine plus 2 row radiator, heater core, water pump, hoses, idler/tensioner pulleys, belt.
All totaled with shop labor and parts i have about $2500-$3000 into the cooling system & brakes rebuild.
Coolant temp runs rock solid at 195* now.
No cooling system worries: Priceless!


Fel-Pro MS 98002 T intake gasket
Engine Water Pump ACDELCO PRO 252-711
Dorman 603-105 Windshield Washer Fluid Reservoir
Stant 45119 195f Superstat Thermostat
Stant 10230 Radiator Cap
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Re: Other maintenance to do when changing intake manifold ga

Postby AstroWill » December 28th 2017, 6:47pm

SportsBoy wrote:My big questions are:
- For an MPFI spider, can I go with this (cheapest) or is ACDelco a must? https://www.summitracing.com/parts/smp-fj503
- Regarding the heater valve and heater bypass valve, I had heat in the back, but got rid of it - do I not need one of these now?
- Is there somewhere you can buy vacuum lines as a set? I've been having a hard time finding anything more than this https://www.amazon.com/dp/B0016IY3QW
- Should I do the head gasket while I'm in there? I'd really like to not have to open it up again in the next 5 years - looking at getting this set https://www.amazon.com/dp/B0016OMSY0. Also, should I get the cylilnder head bolt set if I do this?


That is the spider that I would go with, though it's a little cheaper on amazon http://amzn.to/2CirNEQ
You could get rid of one or both of the heater control valves.
Vacuum lines can be had locally as well as online, just grab some bulk hose, you don't need anything special. If you want to keep the thin tubing instead of the hose, they have that as well in the 'help' section at your LAPS.
Nope, I wouldn't do the head gaskets unless you have a known issue.

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Re: Other maintenance to do when changing intake manifold ga

Postby WimpTech » December 28th 2017, 6:57pm

I just did all this a few months ago, here it is on my build thread: viewtopic.php?f=127&t=103714&start=440

Regarding gaskets, everything I needed was in this kit: http://a.co/4relsvy (sorry if duplicate)

Here are a few notes:
- What got me was the @#$% ground wire that hooks up to the thermostat housing bolt (Thanks again CC)... don't forget that!
- You'll need to change the oil right after too, it will be chocolate milk so don't be alarmed.
- Be super careful not to let anything fall into the various ports, nooks-n-crannies. Little wadded up shop towel goes a long way.
- Careful putting int he EGR pip, its soft metal and can cross-thread easily, especially for ding-dongs like me. After that, it can be a @#$ to get back in right.
- In addition/ in concert with the above, all heater hoses! It's about $100 but good insurance, especially if you do long hauls.

x2 on metal Felpro gaskets, new ACDelco spider and dizzy too BTW
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Re: Other maintenance to do when changing intake manifold ga

Postby Leeann_93 » December 28th 2017, 11:52pm

Don't get the 180° t-stat. Get an AC Delco 195° t-stat. It has a little hole already drilled for relief, I've never had a bad one out of the box (but plenty of bad Stants!). Actually, come to think of it, I've never had to replace the AC Delco stats I put in my '99 or '02...hmm.

Don't bother with the head gaskets unless you HAVE to. If you have leaking or very dirty valve covers, replace those gaskets.

Definitely get the Fel-Pro 98002 T gasket set - that's the one that's plastic-coated metal. Do it once, not over and over.

Between the AC Delco MFI spider and the Skip White distributor, my '02 feels like a new van again.

While you're that far in, see what your upper and lower radiator hoses look like. Check the serpentine belt, tensioner and idler pulley. See if your water pump is leaking and check the bearing.
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Re: Other maintenance to do when changing intake manifold ga

Postby SportsBoy [OP] » January 4th 2018, 10:24pm

Thanks for all the input! Definitely getting the metal Fel-pro gaskets, that's a no brainer.
Also going to get the SW distributor because why not.

Not going to do head gaskets, not too hard to convince me to not do more work :)
I will check my rad hoses, but might hold off from replacing them if they are in good shape still.

Any other thoughts on extra stuff to do while in there?
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Re: Other maintenance to do when changing intake manifold ga

Postby WimpTech » January 4th 2018, 10:53pm

That about covers it, and x2 w/ Leeann, stick to 195 tstat or the gods will punish you.
FWIW- I also did the AC Delco MFI spider and the Skip White distributor, and my '00 also feels like a new van again (thx Leeann).

Might use Ultra Grey on the LIM, as directed. Still not sure if most folks still want goop on the water jackets with that FelPro gasket, I believe i skipped it.

Good luck and please let us know how it goes!
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Re: Other maintenance to do when changing intake manifold ga

Postby WinnieVan » January 4th 2018, 11:49pm

Your in good hands with the advice above! Have fun!
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Re: Other maintenance to do when changing intake manifold ga

Postby 1lowcab » January 5th 2018, 12:08am

Follow the torque sequence and remember to get new manifold bolts.

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Re: Other maintenance to do when changing intake manifold ga

Postby WimpTech » January 5th 2018, 12:11am

Ohhh yeah good call, and make sure you follow the CORRECT Torque spec too, unlike me :rofl:
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Re: Other maintenance to do when changing intake manifold ga

Postby SportsBoy [OP] » January 5th 2018, 5:56pm

Wimpazz wrote:Ohhh yeah good call, and make sure you follow the CORRECT Torque spec too, unlike me :rofl:


Yup, got it bookmarked from another thread.
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Re: Other maintenance to do when changing intake manifold ga

Postby nonhog » January 9th 2018, 10:55pm

Looks like its right around the corner for me too. The tech who is doing my P/S pump just told me its leaking from the intake and VCG's. I knew they were seeping before . Something to add to the list.
Have to decide if I want to do it or have it done here at work?

Great thread! :thumbup:
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Re: Other maintenance to do when changing intake manifold ga

Postby WimpTech » January 9th 2018, 11:35pm

nonhog wrote:Looks like its right around the corner for me too. The tech who is doing my P/S pump just told me its leaking from the intake and VCG's. I knew they were seeping before . Something to add to the list.
Have to decide if I want to do it or have it done here at work?

Great thread! :thumbup:


Make sure its not the heater hoses or the bypass valve, thats why my 'LIM Leak' turned out being...
:2:
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Re: Other maintenance to do when changing intake manifold ga

Postby SportsBoy [OP] » January 10th 2018, 2:21am

@nonhog or anyone reading this thread in the future, here's some links in case you're interested,

Dope step-by-step of it on a 99 Jimmy - http://www.handymanlyness.com/archives/ ... Jimmy.html

Has steps written out, then a picture of the torque sequence (about 3/4 down the page) - viewtopic.php?f=43&t=4645

Halfway down the page there are PDFs outlining the steps and with a crapton of useful info - viewtopic.php?f=43&t=98353&hilit=hoses+replacement

Just ordering the parts for mine now, and tomorrow will be spent opening it up.
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Re: Other maintenance to do when changing intake manifold ga

Postby 1lowcab » January 10th 2018, 2:26am

I used that first link when I did mine, he's got it covered pretty well.
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Re: Other maintenance to do when changing intake manifold ga

Postby Astrofarian » January 10th 2018, 5:37am

^^^^^^X2 on the water pump; nothing like having your "good" water pump poop the bed 2 weeks after you do all this other work. Don't ask how I know, lol.
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