Coolant has been puddling up on the passenger side, on top of the intake manifold, next to the valve cover, for many years. It isn't the heater hoses. A local Chevy dealer couldn't find the source for me (big surprise!) a couple years ago. It just got much worse and the coolant is rolling off the top of the motor now, and onto the garage floor. I barely got it home last night, as the temperature started to spike. Any known issues like this out there with this motor? What is the likely source? What is this likely to cost for repair? THANK YOU!

 

Sounds like you have an intake gasket leak. It might be time tio pull the base and replace your intake gaskets. Sometimes you will see coolant seep up the bolt holes but it should never be as much as you describe. Check your oil to make sure that coolant is getting in there either.

 

Yep, intake gasket. The TPI is notorious for it, although I usually see it on the drivers side front.

 

I would consider myself to be capable with a wrench, but limited in experience when it comes to working on these TPI motors. If this were my GEN II 350 I once had I'd be all over it no problem. I'm pretty sure that a garage would gouge me big time on the labor for this job (TRUE?) so I am resigned to at least attempting it myself. I've got a Haynes manual but their quick and dirty instructions for intake manifold removal and installation leave me a little scared. Are there any other reference manuals out there that would better llustrate how to do a job like this that you know of?

 

Chilton's, shop manual, and TGO are all you will need. I like Haynes for their quick and easy torque spec listings.

 

Well if you can work on a an LT1 you can work on a TPI. Everything as far as intake manifold removal and install will be the same except for the distributor installation and removal. The haynes will be able to tell you how to do it just fine.

Drain coolant
Mark the distributor for installation later (if you are not on TDC)
Remove intake after you get the plenum and runners off.
Clean all mating surfaces down to bare metal. Get all old gasket material off.
3/8" bead of RTV on front and rear of china walls and overlap gaskets a bit. You may also want to put a little around the coolant ports to keep them from leaking later on.
Put everything back together and set the timing once you get the car fired up. (Let RTV sit for a few hours or overnight before you fire the car).

 

I've started to tear down my motor and at this point I almost have the runners off the motor. I say almost because one of the torx bolts got a little chewed up by the bit and because of the funky angle, I can't get it off now. Anybody got any innovative ideas for removing this sucker? I may have to pull off the valve cover to get a better shot at it.

One question too, for shiftycapone if you're out there, or anybody who can help....You mentioned that I should "put a little RTV around the coolant ports to keep them from leaking later on." Please forgive my ignorance, but where should I look for these exactly, on the block, or the heads? Could you describe them in number or location for me, please???

Several people have talked about coolant creeping up the bolt holes in the manifold on these motors. Can I use sealant in those bolt holes, too? RTV?

 

I put the rtv on the gasket. Thin coat on both sides. Permatex #2 on the bolts.

 

Seriously?

It's OK to do that, in addition to the block? DO you do that with valve cover gaskets as well?


Thanks,

R

 

1) Not sure I understand what you are asking.
2) No I personally install them dry.

 

The intake manifold gaskets that go on the heads was my first question....I've got Haynes and Chilton's and neither mentions coating those gaskets with RTV. I'm sure there are at least a few tricks you know about that I don't (this is my first attempt at an intake fix), and that they don't print in those manuals. I am just seeking every bit of advice I can so that this sucker doesn't leak on me when I finally get it back together. If it does, there's gonna be some flying tools and punctured drywall. Thanks!