Just getting ready to replace intake manifold. *** Update ***

[FrustratedUser]

Well some of you guys heard of my car and how great it runs (ran). Now the intake manifold is broken and the mechanic wants $1400 to replace it.
I thought, 'No way I'm paying $1400' so I got a used complete intake from the junkyard for $85 and now I'm preparing to switch myself. The manifold will arrive Monday or Tuesday.
I've been reading the Hayned manual and it seems feasible and pretty much straight forward but it's a lot of work.
The thing that worries me most is how to release the pressure from the fuel injection. The manual tells me to take out the fuse for the fuel pump and run the engine until it stops. The problem is that the intake manifold leaks coolant into the cylinders so it won't run.
Is it bad to disconnect the fuel line with out releasing ther pressure?

The engine is the 3800 series II 3.8 liter V6 used in Buick, Olds, Chevy and Pontiac

First update

Yes, there is a shrader valve on the fuel system, yay!
It began to rain

2'nd update

The fuel injection is now removed. It's difficult.
Next step is to remove sepentine belt and alternator. Can't find the belt tensioner :disgust:
I'm dizzy from gasoline fumes.


3'rd update

Alternator is now removed, easy when I found the tensioner.
Throttle body also removed. Air intake duct removed for easy access to throttle body.
The upper intake manifold is uncovered and can now (maybe) be taken off.
Plan for tomorrow is to try to remove upper intake.
No gasoline fumes today.


4'th update

The old intake manifold is now gone and the new (used) lower part is installed. It went pretty smooth but I would not do it again.
Replaced the thermostat with a 180F (193F stock) since Arizona is HOT.
The rest should not be any huge problem. Basically fit all other parts and then remove moisture from cylinders (partly filled with WD40). Charge the battery and then hopefully drive away.


Update 5

Everything was put together Sunday.
After charging the battery I tried to restart the SOB.
:disgust: It won't fsking start. Aaaaah...... Battery is now dead again. It's probably flooded or contains remains of some coolant+WD40 and that sure don't burn. I'm pissed.
Will leave it overnight with sparkplugs taken out. I hope it will dry up.
:|


Update 6

In the battle 'Man vs. Car', I declare myself the winner.
It's running again!
Next step is an oil+filter change and a set of new spark plugs.
Everyone in this thread gets a cookie for support and help. OK, I was slow but for a complete no0b in car surgery I am pleased. Saved $1400 - ~$300 in parts = Saved $1100!

 

[Krakerjak]

I looked through my manual and it mentioned this:

Disconnect the fuel lines - NOTE : The fuel lines may be under pressure , use extreme care when removing them


Seems as though it shouldnt be a problem, though i would be wary if i were doing it.

 

[yakko]

Does that engine use EFI? If it does it will be low pressure and also since you probably haven't run the car in a while I doubt there will be much pressure anyway. When I had to remove a feul line that was under pressure I would always get the wrench on it securely and then throw a shop rag over it so if it did spray it wouldn't go anywhere.

 

[Pepsi90919]

my bonneville has the Series I 3800... IIRC you might be able to just take off the whole fuel rail without removing the fuel line.

besides that, it matters not that your engine runs. the injectors just need to pulse the fuel out of the lines, that's all. i know mine won't run at all when you remove the fuse.

 

[FrustratedUser]

Originally posted by: Pepsi90919
my bonneville has the Series I 3800... IIRC you might be able to just take off the whole fuel rail without removing the fuel line.

besides that, it matters not that your engine runs. the injectors just need to pulse the fuel out of the lines, that's all. i know mine won't run at all when you remove the fuse.

Maybe that's possible. I'm having some coffee now to build up confidence. I also need to find the correct set of gaskets.

 

[JC]

There should be a Schrader valve (like a tire valve stem) on the fuel rail, you can use a small tool to depress the stem (like letting air out of a tire) with a rag over it so you don't get sprayed.

JC

 

[Cyberian]

The thing that worries me most is how to release the pressure from the fuel injection. The manual tells me to take out the fuse for the fuel pump and run the engine until it stops. The problem is that the intake manifold leaks coolant into the cylinders so it won't run.
Is it bad to disconnect the fuel line with out releasing ther pressure?

I haven't worked on car engines for a long time, but should an intake manifold be leaking coolant anywhere?

 

[notfred]

jsut disconnect the fuel line, a little gas will drip out, and you wipe it up, and you're good to go.

 

[FrustratedUser]

Originally posted by: JC
There should be a Schrader valve (like a tire valve stem) on the fuel rail, you can use a small tool to depress the stem (like letting air out of a tire) with a rag over it so you don't get sprayed.

JC

I'll check into that too. Thanks.

 

[FrustratedUser]

Originally posted by: Cyberian

The thing that worries me most is how to release the pressure from the fuel injection. The manual tells me to take out the fuse for the fuel pump and run the engine until it stops. The problem is that the intake manifold leaks coolant into the cylinders so it won't run.
Is it bad to disconnect the fuel line with out releasing ther pressure?

I haven't worked on car engines for a long time, but should an intake manifold be leaking coolant anywhere?

It should not leak coolant into the cylinders. At first I thought it was the head gasket but the mechanic said it was not. Changing the intake is easier than ripping the heads off.

 

[tcsenter]

I haven't worked on car engines for a long time, but should an intake manifold be leaking coolant anywhere?

It could if it's cracked or the intake gasket has failed and the thermostat housing is inside the intake or the return coolant hose comes out of the intake...as it does with the 3800 and most other OHV pushrod engines.

 

[Pepsi90919]

3800's have this really F'ed up coolant passage that goes through the manifold and hits the throttle body.

 

[notfred]

Originally posted by: FrustratedUser

Originally posted by: Cyberian

The thing that worries me most is how to release the pressure from the fuel injection. The manual tells me to take out the fuse for the fuel pump and run the engine until it stops. The problem is that the intake manifold leaks coolant into the cylinders so it won't run.
Is it bad to disconnect the fuel line with out releasing ther pressure?

I haven't worked on car engines for a long time, but should an intake manifold be leaking coolant anywhere?

It should not leak coolant into the cylinders. At first I thought it was the head gasket but the mechanic said it was not. Changing the intake is easier than ripping the heads off.

You're right, but it can still leak coolant into the oil.

 

[FrustratedUser]

Originally posted by: notfred

Originally posted by: FrustratedUser

Originally posted by: Cyberian

The thing that worries me most is how to release the pressure from the fuel injection. The manual tells me to take out the fuse for the fuel pump and run the engine until it stops. The problem is that the intake manifold leaks coolant into the cylinders so it won't run.
Is it bad to disconnect the fuel line with out releasing ther pressure?

I haven't worked on car engines for a long time, but should an intake manifold be leaking coolant anywhere?

It should not leak coolant into the cylinders. At first I thought it was the head gasket but the mechanic said it was not. Changing the intake is easier than ripping the heads off.

You're right, but it can still leak coolant into the oil.

It does both so I'm out of luck here.

 

[tcsenter]

3800's have this really F'ed up coolant passage that goes through the manifold and hits the throttle body

F-ed up, maybe, but pretty much standard for decades on domestic pushrod engines. Check the Holley or Eldebrock catalog some time, many many manifolds with thermostat housings in the intake.

 

[FrustratedUser]

I'll keep this thread updated on the progress. This is my first attempt of engine surgery.

 

[tcsenter]

I'll keep this thread updated on the progress. This is my first attempt of engine surgery.

heh, good luck! I completely overhauled (top and bottom) the ancestor of the 3800, 231cu Even Fire V6 from a 1978 Buick Regal. I had a shop rebuild the heads, turn the crank, hot tank the block, blow the oil gallies out, and install the cam bearings, but outside of that, I did everything else in my dad's garage when I was 17. FUN!

 

[Pepsi90919]

Originally posted by: tcsenter

3800's have this really F'ed up coolant passage that goes through the manifold and hits the throttle body

F-ed up, maybe, but pretty much standard for decades on domestic pushrod engines. Check the Holley or Eldebrock catalog some time, many many manifolds with thermostat housings in the intake.

well i still say it's F'ed up.

 

[FrustratedUser]

First Update.

Yes there is a shrader valve on the fuel system. yay!

It began to rain.

 

[yakko]

Originally posted by: FrustratedUser
First Update.

Yes there is a shrader valve on the fuel system. yay!

It began to rain.

That isn't rain. That is a sign you do not have enough beer to be working on a car yet.

 

[FrustratedUser]

Originally posted by: yakko

Originally posted by: FrustratedUser
First Update.

Yes there is a shrader valve on the fuel system. yay!

It began to rain.

That isn't rain. That is a sign you do not have enough beer to be working on a car yet.

LOL!
Something comes down from the sky anyway.

 

[SuperSix]

Getting coolant into the OIL shouldn't be an issue,you should always change the oil after such surgery..

Let me know if you need it, and I'll send you the R&R info from Mitchell On Demand. WHat year car?

<-- has owned multiple 3800's

 

[FrustratedUser]

Originally posted by: SuperSix
Getting coolant into the OIL shouldn't be an issue,you should always change the oil after such surgery..

Let me know if you need it, and I'll send you the R&R info from Mitchell On Demand. WHat year car?

<-- has owned multiple 3800's

It's a 1997 oldsmobile Regency. I am not afraid of getting coolant in the oil now when it's broken.
Please send the info you have.

I just went out in the rain and started removing the throttle body. Damn description in Haynes is not correct. It looks different.
I've unplugged the vacuum hoses and the fuel line is easy to disconnect.
To be able to remove the throttle body I have to remove the fat coolant hose coming from the radiator.
Now it's raing heavy so I'm here instead.

 

[FrustratedUser]

Updated!

 

[slag]

ask away on www.clubgp.com

The process has been done there many times and they can give you pointers. I have a Supercharged 3.8 aluminum intake. Yours is plastic, isnt it?