PontiacBonnevilleClub.com

I know other people have made a list asking if they are missing anything and I'm kind of doing the same thing. But also this to make sure i have the right parts lined up, I should be ordering in a few weeks

From Intense:
Lower Intake Gaskets (L36) GMG-I36
Upper Coolant Elbow GMH-CEU
N/A Upper intake Kit GMG-L36UIG
99+ Lower Coolant Elbow GMH-CEL

From Autozone:
Felpro Valve Cover Gasket VS50080R
Felpro Fuel Injector O-Ring (Upper Set) ES71192
Felpro Fuel Injector O-Ring (Lower Set) ES71190
Permatex 3 oz. (88.721 ml.) Tube Ultra Copper Maximum Temperature RTV Silicone Gasket Maker 81878
4 Gallons (2 if not Pre-mixed) of Prestone Any-type

Is this for the SE? If so, unless you have already replaced the stock UIM with an APN or sleeved the EGR passage yourself, I would recommend you install an APN UIM kit while you are doing all the other stuff. The APN kit includes some of the parts you are planning to buy separately. All this is explained in this Techinfo article: 3800 Intake Manifold Issues

Here is a list of stuff for doing UIM/LIM gaskets on an L36 (normally aspirated '95-'03):

GM aluminum frame lower intake manifold gaskets
APN upper intake manifold kit
Dorman Help pack of two coolant elbows
GM tensioner seal (95-98, o-ring from tensioner nipple to water pump)
O-rings for fuel injector nozzle for 2000+ (APN kit includes only the larger rings for 95-99)
Brake parts cleaner - 2 or 3 cans
Shop rags
One gallon of "mix with any" coolant
If you re-use your coolant, you will need a funnel and some panty-hose to use as a filter.
Heavy scraper
Thermostat housing gasket (paper for older models)
Thermostat (180F)
Thermostat seal (rubber)
1/16" or 5/64" drill bit to drill thermostat flange
4 quarts of oil and a filter
Throttle body cleaner
Alcohol and Q-tips for MAF cleaning if needed
Silicone grease for o-rings
Vacuum cleaner
Hand vacuum pump or wet-vac to remove residual coolant from LIM
Valve cover gaskets if they are leaking
Blue threadlocker
Torque wrench capable of accurately measuring 89 in-lb (7.5 ft-lb)
Parts cleaning solvent or kerosene and a plastic pan
A couple of old toothbrushes (for throttle body cleaning)
Wire brush for cleaning up LIM and UIM bolts
New vacuum fittings from the dealer for the throttle body as needed

Techinfo article explaining how to: Change UIM/LIM Gaskets

The APN UIM is a nice piece of equipment and they have FAST shipping. Get the LIM gaskets from GMpartsdirect.com for the best price. Also order the injector o-rings from GMPD. Those 6 o-rings cost $20 at the freaking dealer! If you want to re-use your older UIM, keep in mind mine was in very good shape when I took it off. That does not mean yours will be for sure though. Better safe than sorry. I think you mentioned the repair kit from intense, that may be a better/cheaper option. If you have coolant in your oil, and you're not doing this as preventative maintenance then I would recommend the new UIM.

I'd get the APN UIM, for peace of mind. You only want to do this job once. Don't get the coolant elbows from Intense, they are $5 at Advance. You only need 2 gallons of Pre-mixed coolant.

OK i was going by the capacity specs form Alldatapro for the amount of coolant i needed which AllData claims 13 Quarts which breaks down to almost 4 Gallons I will look into GMPD for the parts and will add the APN UIM to the list which also comes witht the gasket. I definatly only want to do this once and your right in asking that this being done as a repair not as maintenance but fortuantly no coolant is getting into the oil at this point but before i added the pellets was getting a good amount of coolant in the front side of the engine and on the top of the engine near the valve cover. Valve covers will also be getting changed as the front valvwe cover is leaking as well as could be adding some new plugs and wires as it might be easier to get to the back 3 plugs while working on the intakes

What you likely saw at AllData is the cooling system capacity, which includes the radiator, as well as all the engine passages. Roughly half of that is the radiator.

ok well I ordered my parts today through work the Dorman Plenum kit has already arrived and the other parts are on their way from our Pontiac dealer, All except the Fuel Injector O-rings I won't get those until thursday

biohazed wrote:...the Dorman Plenum kit has already arrived...

Is that a typo or did you buy a Dorman instead of an APN? If so, could you let us know why you chose the Dorman and how much you paid for it?

I have a leak in the exact same spot so I'll be repairing mine soon too. Not really looking forward to it because my Bonnie is my only car, so I really can't afford for it to be out of commission more than a weekend.

Oh well

no it was not a Typo I did get the Dorman Kit for the main reason is that is was readily available and according to the parts dept at our Pontiac Store they recommened the the Dorman kit as a repacement ... plus working for a dealer has its avantages ... heres my price list:

Dorman UIM Kit :$60
GM Aluminum Intake Gasket $30
Toyota Thread Locker (same as GM's just has a Toyota Logo): Free
GM Upper and lower Coolant Elbow set: $6.00
GM Injector O-Ring Set :$6.95
10 Quarts of 10w-30: Free
1 Champ Oil Filter: $1.00
1 tube of copper RTV: Free
2 Gallons of Prestone Anytype $12.95 (parts store)
1 Fuel Pressure Vacuum line (mine was broken) $7.00

The Sad thing is I really didn;t need the GM O-Ring set as the Dorman Kit has a set in it already

I started on it on Wednesday and due to some parts mix up I got held up till froday and due to customers coming in it's still not done but its gone like this so far:

Wedsnesday: Main strip down of engine removal of everything
Thursday: Intake gets put in the Cuda Parts washer and gets cleaned up and replaced Valve cover gaskets and ported lower intake
Friday: All surfaces cleaned and lower intake and Aluminum LIM installed
Saturday: Installed upper and lower coolant elbows and installed new UIM. CLeaned carbon out of throttle Body, re-installed Throttlebody
Monday plan to reinstall Fuel injectors and fuel rail re-hookup Sensors Fuel Pressur Regulator Vacuum Line add coolant, and Test Start
Drain oil and refill with motor flush chemical run for 5 minutes and flush again
Install new filter and fresh oil button up car.

so in theory Monday i should be done

Wow! No wonder you got the Dorman. They usually sell for $150 at O'Reilly's. Those are really good prices! Have you changed the fuel injector o-rings yet? When my son and I did his 2001 SSEi, we needed a smaller ring for one end of the injectors. Does the Dorman kit provide two sizes of o-rings, or maybe the L36 injectors are different in that they use the same injector o-ring for the LIM end and the fuel rail end?

they are 2 different sizes and not sure yet as I haven't gotten to replace the o-rings and put the injectors back in yet ... but monday should be dead so I hope to get my car finished and back on the road (I miss it so much .. can't take the Blazer with the broken drivers side seat for much longer lol)

ok actually the injector o-rings are the same size for top and bottom ...

I got her finished last night however I got a code ... Coolant Sensor High.. and low and behold i broke the fornt coolant sensor so i replaced it this morning and she is purring like a kitten.

Cool!! Great to hear you got it running again!