GM 3.8L IMG - stuck removing manifold

[tomcat27]

Friends car - he forgot to pickup the chiltons manual. we have the intake plenum removed and all the bolts from the intake are out. the manifold moves around but we cant lift it out. there appears to be a black L-shaped thing on the passenger side in the middle holding it. and do you need to remove the upper engine mount brackets? Also, I can see where the upper plenum gasket was leaking coolant, does the lower really need replacing?

 

[moklock]

Be certain all bolts are out. two that are recessed can be hard to find if the intake is really gunky.

The plastic elbow(s)- you may have two down there depending on the car, are supposed to just wiggle out but often just break at the o-ring groove leaving a bit of plastic to pull out of the manifold or tensioner. Either way don't reuse those, replace with new.

 

[Colt45ws]

If you already popped the bolts for the lower, have it loose, yes it needs replaced. Doubtful it will seal a second time.

 

[tomcat27]

cool! the manifold is off! yup - there were 2 bolts "hidden" in puddles of oil.
Now, about the black plastic thing - it did break. what is it? it goes from the intake to the tensioner. does it hold coolant? whats it called?

 

[The_Cams]

I think you're talking about the plastic coolant elbow (heater hose bypass) that goes from the LIM to the belt tensioner. Yeah, coolant goes through it. Parts stores have them on their "HELP!" rack. Dorman part # 47065 if it's a GM 3.8L 1995-2007. You may have to dig into the manifold and tensioner hole to get all the plastic out.

 

[tomcat27]

yup! exactly! thanks! sorry, thats some goofy engineering! so both the IM and the intake plenum are in place with new gaskets - all properly torqued. gotta wait for the correct thermostat - my buddy picked up a 180, not a 195. besides, its late. finish it tomoorrtow. thansk all for the help!

 

[sciphi]

You're fine with the 180. I'm running one in my 3800-powered Buick. The computer doesn't know the difference, since it gets the exact same fuel mileage as with the 195 stat. The slightly lower temperature helps keep the plastic gaskets and upper intake manifold intact a bit longer. This is something to keep an eye on if you used the Fel-Pro nylon gaskets and Dorman unit instead of the APN unit and GM aluminum gaskets.