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Inside Sealing GM 3 1L 3 4L Engines Who For shop owners and technicians What Tips for engine sealing repairs Where Visit www felpro only com for more information Why Leverage the expertise of the Fel Pro engineering team to grow your engine sealing business Highlights Intake manifold gasket selection and fit Facts about engine hardware Push rod length considerations Correctly installing PTFE rear main seals Other sealing repair opportunities One of the most common engines on the road today the General Motors 3 1L 3 4L V6 represents a large service and repair opportunity for engine professionals This platform was established in the 1980s as a 2 8L engine In the early 1990s GM engineers increased the displace ment and applied the two larger engine models to an ex tensive range of applications from the Chevrolet Citation and Camaro to the Oldsmobile Silhouette and Pontiac Transport minivans and Pontiac Aztec SUV The technical recommendations and products featured in this bulletin are based on extensive customer input to Federal Mogul s engine sealing team In addition Fel Pro product engineers in Skokie Ill work closely with engine specialists within the company s global network of techni cal research facilities to develop innovative solutions to the latest sealing challenges encountered in the repair environment Common Leaks Among the most commonly reported GM 3 1L 3 4L sealing issues are 1 premature failure of nylon type intake manifold gaskets 2 head gasket failure 3 rear main seal leakage and 4 oil pump drive O ring failure Fel Pro Solutions 1 PermaDryPlus intake manifold gaskets 2 PermaTorque PermaTorqueSD head gaskets 3 PTFE rear main seal 4 Distributor mounting O ring A Closer Look at a GM Workhorse GM 3 1L 3 4L Application Engines in Service 1993 1999 VIN M 3 1LV6 4 401 054 1999 2005 VIN J 3 1L V6 1 316 031 1999 2004 VIN E 3 4L V6 3 997 966 FPO 0308 150 www felpro only com Intake Manifold Gasket Repairs Technicians and rebuild ers have reported that many 3 1L 3 4L cylinder heads exhibit moderate to severe pitting around the coolant ports While new Fel Pro PermaDryPlus in take manifold gaskets are capable of sealing a wide range of surface imperfec tions in cases of extreme pitting the casting should be repaired or replaced before continuing Check for Pitting of Gasket Mating Surfaces It is not unusual to en counter an engine with a non original head that has been swapped between a 3 1L and 3 4L engine during an earlier repair In other words never assume you have the right cylinder head when beginning the repair doing so might cause you to install the incorrect replace ment gasket Do not rely on the cast ing number to identify the cylinder head on a 1993 2005 GM 3 1L or 3 4L engine The only way to verify head design on these applica tions is to match the intake port dimensions and pin location holes with the corresponding replacement gas ket The gasket pin must precisely fit the location hole If the pin does not fit check the other head you might have inadvertently swapped gaskets The Fel Pro PermaDryPlus intake manifold gasket is designed specifically to ad dress the challenges of the aftermarket repair environment The gasket fea tures an aluminized steel carrier that is encapsulated with a proprietary fluoroelastomer rubber compatible with all types of oil and coolant Three separate beads around the cool ant ports ensure a permanent seal Beware of Swapped Heads When performing an intake manifold sealing repair on a GM 3 1L or 3 4L engine it is a good idea to replace the intake manifold bolts Any loss of torque could lead to a repeat sealing is sue and potentially severe engine damage according to Fel Pro Senior Engineer Jerry Rosenquist Fel Pro offers a complete line of replacement intake manifold bolts when re quired for the repair The Fel Pro bolts for GM 3 1L 3 4L engines are ideally suited for use with PermaDryPlus intake manifold gaskets as well as the standard gasket set offering for these engines See parts listing below Always follow the manufac turer s latest torque speci fications Fel Pro includes torque specifications on the I Form installation instructions packaged with gasket sets and with the bolts themselves Getting it Tight Facts About Intake Manifold Bolts YEARS PART DESCRIPTION 05 01 ES 72225 VIN Code J 00 ES 72225 VIN Code J Exc Malibu model 00 ES 72226 VIN Code J Malibu model 99 ES 72225 VIN Code J 99 93 ES 72225 VIN Code M YEARS PART DESCRIPTION 05 01 ES 72226 VIN Code E Car and Truck 00 ES 72226 VIN Code E Alero Grand Am models 00 ES 72225 VIN Code E Impala Monte Carlo models 00 96 ES 72225 VIN Code E Truck 99 ES 72225 VIN Code E Car Fel Pro Intake Manifold Bolt Sets GM V6 189 3 1L 1999 2005 VIN Codes J M GM V6 207 3 4L 1996 2005 VIN Codes E Car Truck If your gasket pin doesn t align with the location hole as above chances are you re working on a non original head that s been swapped between a 3 1L and 3 4L engine during an earlier repair Intake Manifold Gasket Repairs When ordering replace ment pushrods for a GM 3 1L engine double check intake and exhaust push rod lengths Intake push rods for these engines should be 5 676 in length and exhaust pushrods 6 004 in length Installing the wrong pushrods will lead to engine damage Pushrod guides are anoth er important consideration In some 1993 95 engines the pushrod guides are intregal to the intake mani fold gasket while in others they are part of the cylin der head itself The best solution is to rely on the Fel Pro PermaDryPlus se ries of gaskets that accom modate both designs Double Check Pushrod Lengths And Guides Before Assembly Premium Leak Sealing Technologies PermaDryPlus Problem solving gaskets featuring advanced technologies designed specifically for the aftermarket repair environment PermaDry Premium molded rubber gaskets for applications originally equipped with molded rubber technology Doing the Complete Job Replac ing intake manifold gaskets on GM 3 lL 3 4L engines is a little more complex than other common sealing repairs We ve done quite a few of them in the Fel Pro test lab and have used this experience com bined with our materials expertise to develop the best replacement gasket technologies As with any important repair make sure you have the right parts before beginning the job and always follow the preferred repair sequence to en sure a perfect seal The parts you ll need are new intake manifold bolts with threadlocker applied push rods verified to the cor rect lengths rocker arms Fel Pro PermaDryPlus replacement intake mani fold gasket s and RTV sealant As you may know the Fel Pro PermaDry and PermaDryPlus names mean install this gasket dry The use of RTV in this job is not associated in any way with the Fel Pro gas ket so do not apply RTV to the gasket or its mating surface The RTV is to be used only in forming the end seals on the block Once you ve got all of the right parts apply the RTV beads for the end seals and then install the intake manifold gasket being careful to align the pin lo cation holes with the pins Next install the push rods and rocker arms and snug them down then install and torque the intake man ifold to specifications The next step is to torque the rocker arms to spec and finally reinstall the valve cover with a new gasket You can add value to this important repair by replacing the thermostat and flushing the cooling system It s extremely dif ficult to access the ther mostat on these engines unless the intake manifold is removed chances are the customer will need a new stat before needing another sealing repair so do the complete job now for enhanced customer convenience and satisfac tion Why flush the cooling sys tem The introduction of air to the engine s long life coolant will degrade the coolant chemistry This is a common problem on older engines where loose hose clamps and low coolant levels can cause air to be sucked into the cooling system John Gurnig runs the Fel Pro Field Test Garage in Skokie Ill He usually can be found under a hood out on a road test or back in the Fel Pro dyno lab Preferred sealing repair process for GM 3 1L 3 4L engines By John Gurnig Field Test Technician John Gurnig Other Repairs GM 3 1L and 3 4L engines feature an oil pump drive at the original location of the distributor in the old 2 8L The original equip ment O ring which seals high pressure oil is highly susceptible to hardening and contamination and should be replaced as part of any other sealing repair Fel Pro has developed an exclusive FKM O ring material that stands up to the high temperatures en countered in this location The Fel Pro O ring is in cluded in all PermaDryPlus MS98000T series intake manifold repair sets Fel Pro en gineers have developed an exclusive PTFE rear main seal that provides a longer lasting reduced drag highly temperature resistant solution for GM 3 1L and 3 4L engines These aftermarket engi neered seals are ideally suited to the repair environ ment and help provide an extra margin of protection against a comeback It is crucial to note that PTFE seals should only be installed dry This enables a portion of the PTFE material to be transferred to the shaft which ensures proper sealing perfor mance Also be cer tain that the seal is installed straight within the bore Oil Pump Drive O Ring Issues Rear Main Seal Solution Only Fel Pro offers 100 application specific sealing solution components for GM 3 1L and 3 4L engines And each Fel Pro gasket and seal for these applications features the best material and design for the aftermarket repair environment 3 1L 3 4L Parts Check Leak Repair Valve Cover Gaskets Valve Cover Grommets Intake Manifold Gaskets Intake Manifold Bolts Distributor Mounting O rings Oil Pan Gaskets Oil Pan Drain Plugs Oil Cooler O rings Timing Cover Gaskets Seals Rear Main Bearing Seals Oil Filter Adapter Gaskets Drivetrain Transmission Pan Gaskets Differential Cover Gaskets Cooling System Thermostat Gaskets Water Tube O rings Thermostat Bypass Seal Gaskets Water Pump Gaskets Engine Repair Valve Stem Seals Head Gaskets T T Y Head Bolts Exhaust System Repair Exhaust Manifold Gasket Exhaust Pipe Packing Fuel System Throttle Body Mounting Gasket Fuel Injector O rings Fuel Rail O rings Idle Air Control Seals Upper Plenum Chamber Gaskets EGR Gaskets Repair Type Repair Type Premium Materials Upgrade Available PermaDryPlus Intake Manifold Gaskets SD Severe Duty Head Gaskets PTFE Rear Main Seals
