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Old 10-18-2006, 12:48 AM   #11
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I guess my weekend plans have changed. I have never gone this deep into the engine, so it might get ugly.

Wish me luck. . . . . . .
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Old 10-18-2006, 09:47 AM   #12
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Quote:
Originally Posted by jastek1
I guess my weekend plans have changed. I have never gone this deep into the engine, so it might get ugly.

Wish me luck. . . . . . .
It won't be ugly if you look at it this way.
Our engines and cars are only a lot of parts held together by a lot of nuts and bolts.

When you take things off.. put them with their fasteners. Face them the right way where you put them, so there'* no question which way they go back on. Take pictures.. then..review the pictures and see what you took off in what order if you forget what order to put things back.

You can remove the supercharger, alternator, throttle body and lower intake with the following tools.

8mm socket (battery disconnection only)
10mm socket
13mm socket
a 3" extension
a 6" extension
Ratchet
bucket for coolant

In reality the alternator can stay on the car. it'* easier w/o though.
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Old 10-20-2006, 12:29 AM   #13
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Thanks for the tips. I will let you know it goes.
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Old 10-20-2006, 12:46 PM   #14
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89017825 - Lower Intake Manifold Gasket
24503911 - Upper Intake Manifold Gasket
24503648 - Throttle Body Gasket (Only necessary if you pull the TB to clean it...you can leave it installed to the */C when removing it.)
24503423 - Plastic 90 degree Coolant Hose (Front of intake manifold)
24501563 - Yellow O rings (Need 2)

Just did mine yesterday...took maybe 2 half days to complete. All local parts places had to order everything that I needed but my dealer had it all in stock. Prices were only a couple dollars higher at the dealer on a few items than local places. You could probably use the 90 degree hose and yellow O rings over again but I'd kick myself in the *** if I broke down because I was too cheap to replace that hose. Atleast replace the O rings on the 90 degree hose if you should reuse it. Dealer did not have the injector O rings in stock so I just reused them. Just make sure that you clean out the injector holes and use some sort of lubricant before reinstalling them. Also, I found it easier to install the injectors into the fuel rail first and then press them into the heads...if pressing doesn't work on all injectors, I used a mallet and a drift to tap the fuel rail above the injector VERY LIGHTLY...just make sure that the injector in lined up perfectly.

Another item that you should replace is your left/front valve cover gasket...they are prone to leaking and would take very little time to replace with everything else apart.

Make sure you change your oil after it is all together. You may get a little water running down into the pan when removing the manifold.

I did not find it necessary to remove the alternator.

My intake used a 3/8 socket...but everything else was metric.
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Old 10-20-2006, 01:38 PM   #15
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I personally..don't remove the injectors from the fuel rail. Nor the rail from the fuel lines. It'll flop out of the way easy enough. Saves a couple minutes.

The nice thing about the Fel pro SC to LIM gasket is it comes with the O rings. (Not sure why GM wouldn't put them in the same package)

On the 3/8 socket. "Supposedly" all the bolts on our cars are metric... I totally agree on a 3/8 fitting better on these bolts and have done so.
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Old 10-20-2006, 05:28 PM   #16
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Don't forget a good torque wrench! Also, as stated, replace the valve cover gaskets while you have things apart. To do that, you'll have to remove the alternator and brackets. While you're at it, remove the tensioner, and replace the second coolant elbow that runs off the lower left of the tensioner. As it also serves as part of the mounting bracket for the alternator, you'll have to remove it if you do the valve cover gaskets, anyway.

I also just remove the fuel rail as an assembly and move it aside without removing the injectors from the rail, or disconnecting the fuel lines. I then buy the GM LIM gasket, and Felpro for the upper(or supercharger). Both coolant elbows come in one package in the Dorman "Help" products at Autozone, Pep Boys, and several other auto parts stores. The local Advance did not carry them. Boosty had a problem with one of those elbows deforming. I've used them in 4 vehicles without an issue so far.
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Old 11-06-2006, 06:08 PM   #17
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Saturday was LIM gasket day. All went well and I am back up and running, LEAK FREE !

Total time to complete was 10 hours ( only 1 trip to the parts store for things I forgot ).

Early in the job I got a little freaked out by amount of hoses, wires and brakets that had to be removed just to get the fuel rail off, but I pushed through and got er done. Once you get past the fuel rail removal, things move along pretty quickly.

After getting the LIM gasket off, there was no real obvious leak location, but I know it was there.

I did have a couple problems with vacuum hose connectors that crumbled on me, all of which are dealer parts. I had to make replacements out of pieces from Dorman Help tubes, elbows and hoses.

One other problem I had was on the injectors. There is a hard (brittle) disc that sits at the very bottom of the injector, just below the O ring. I broke about 1/4 of this disc off on 2 of the injectors. Since the injectors are about $75 each, I took a chance and just reinstalled them with the broken discs. So far, there are no problems. As best I can tell, these discs have no real purpose other than securing the O ring. Can soemone tell me what the purpose of that disc is ?

I took a photo of the engine without the SC and LIM just to prove that I did the job, but I don't know how to post it.

Thanks to everyone who gave me tips on getting this done, especially BIllBoost for his photos and blow by blow. I have a 2001, so things were a little different, but I followed his post step by step and it got me through it.
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