I just replaced the head gaskets on my 96 3.8l and I now have water and oil mixing in intake and after a week it's starting to get into motor oil on dip stick. Has anyone done a intake manifold gasket job and maybe give me a break down on steps and locations of all o-rings.

 

i was going to do it once, dint end up being the problem but my chilton manual had the info

 

My hanes has some but does yours have anything different?

 

I replaced the gasket that goes between the plenium and intake( if that is the one you are talking about). It came with 3 orings. The red one and yellow one fit under the thermostat housing. I could not find a place for the black oring that was in the kit.

I followed the steps in the Haynes manual but my engine was out of the car. There are several (what I call hidden) bolts around the plentium and you have to remove the thermostat housing bolts before the plentium will lift off the intake. Be sure to torque the bolts according to the sequence in the manual and to the right specs.

You will have to remove the fuel rail and coil packs and wiring harness to the injectors before you can even get to the bolts that hold down the plentium.

 

get yourself a dealer sevice/shop manual for your yr and model. they are much more inclusive that the aftermarket books. heres one that u can look (or bid on) at so u know which one to get.
http://cgi.ebay.com/ebaymotors/96-CA...#ht_606wt_1124

 

Found problem, plenum gasket at thermostat pass thru leaked as I didn't realize one bolt in thermostat housing also torqued front of upper intake. Was leaking into first cylinder on drivers side. Have to get new gasket kit but better than doing it all over again. Thanks for the info and help.

 

Be sure to change the oil before firing up the engine again.

 

Yea on the oil change. That has to be the dumbest way to secure a intake. Every time you change the t-stat you have a chance of this problem. Defiantly better news than another blown head gasket.