A few months ago, I had a coolant leak. Ford garage installed thermostat asy, gasket, valve rocker arm cove, intake gasket kit and sealant--$900. Now another leak. They now say need to replace freezer plug(s)--$300+!!!!!! Should they have done the plugs the first time also??????????????

Hi there:

Rocker Arms & Pushrods

Removal & Installation

3.1L & 3.4L Engines
Left Side

1. Before servicing the vehicle, refer to the precautions section.
2. Drain the cooling system to a level below the coolant pipe on the front of the engine.
3. Remove or disconnect the following:
   NOTEKeep the pushrods in order. Intake pushrods are 5 3 / 4 inches long and exhaust pushrods are 6 inches long.
   
   
   Negative battery cableSpark plug wiresHeater bypass pipePositive Crankcase Ventilation (PCV) valve and hoseRocker arm cover
   
   
   Rocker arms and pushrods
   

To install:

1. Lubricate all the valvetrain components with engine oil.
2. Install or connect the following:
   
   Pushrods and the rocker arms. Torque the bolts to 24 ft. lbs. (32 Nm).Rocker arm cover using a new gasket. Torque the rocker cover bolts to 89 inch lbs. (10 Nm).PCV valve and hoseHeater bypass pipe. Torque the screw at the water pump to 106 inch lbs. (12 Nm), the bolt at the cylinder head corner to 18 ft. lbs. (25 Nm) and the nut to 18 ft. lbs. (25 Nm).Spark plug wiresNegative battery cable
   
3. Refill the cooling system.
4. Start the vehicle and verify no leaks.

Right Side

1. Before servicing the vehicle, refer to the precautions section.
2. Remove or disconnect the following:
   NOTEKeep the pushrods in order. Intake pushrods are 5 3 / 4 inches long and exhaust pushrods are 6 inches long.
   
   
   Negative battery cableAlternator bracket on 2005 modelsSpark plug wires from the spark plugs and the upper intake plenum wire retainerPower brake booster vacuum pipe from the intake plenumAccessory drive beltAlternator, if necessaryIgnition coil assembly and Evaporative Emissions (EVAP) canister purge solenoid as an assemblyRocker arm cover
   
   
   Rocker arms and pushrods
   

To install:

1. Lubricate all the valvetrain components with engine oil.
2. Install or connect the following:
   
   Pushrods and the rocker arms. Torque the bolts to 24 ft. lbs. (32 Nm) plus an additional 30 degree turn.Rocker arm cover using a new gasket. Torque the rocker cover bolts to 89 inch lbs. (10 Nm).Ignition coil and EVAP solenoid assemblyAlternator, if removed. Torque the bolts to 37 ft. lbs. (50 Nm).Accessory drive beltPower brake booster vacuum pipe to the plenumSpark plug wiresNegative battery cable
   
3. Start the vehicle and verify no leaks.

Hope this helps.

Intake Manifold gasket replacement fixed my very similar issue. New ones from GM are aluminum w/rubberized gasket - old ones plastic with a rubberized gasket - common failure in the 80-100k mile range. My mechanic did it for $620 included sealant,thermostat,valve cover gasket, gasket kit, coolant,pipe,pipe, manifold t and supercharger gasket.

do you have a coolant leak or oil leak. ive always discarded the rubber gaskets provided in gasket kit, and instead, ran a good thick bead of silicone. The rubber gaskets, ive found, can be pushed out, either when setting intake on engine, or if the engine has a bad pcv valve, pressure within block can blow them out. make sure and check pcv valve. after the new intake gaskets are placed on the head, dab a bit more on the 4 corner nubs of the gaskets. i like to use an anearobic sealer around the coolant ports, just thin layer on both sides of gasket. hope this helps. James White, White Auto, Hopkins Mo. 17 yr ASE tech.

Removal

1. Drain engine cooling system.

1. Disconnect battery ground cable (14301) .

1. Remove engine air cleaner (ACL) (9600) including air cleaner outlet tube (9B659) .

1. Loosen drive belt tensioner (6B209). Remove drive belts (8620) .

1. If LH cylinder head (6049) is being removed, perform the following:
   1. Remove oil filler cap (6766) .
   1. Remove power steering pump front mounting bracket retaining bolts.
   1. Remove generator (GEN) (10346) and belt idler pulley (8678).
   1. Remove power steering pump/generator bracket retaining bolts. Leave hoses connected, place pump/bracket assembly aside in a position to prevent fluid from leaking out.

1. If RH cylinder head is being removed, perform the following:
   1. Remove drive belts .
   1. If equipped with A/C, remove mounting bracket retaining bolts. Leave hoses connected and position A/C compressor (19703) aside.
   1. Remove positive crankcase ventilation valve (PCV valve) (6A666) .

1. Remove upper intake manifold (9424) .

1. Remove valve cover retaining bolts.

1. Remove fuel injection supply manifold (9F792).

1. Remove lower intake manifold as outlined.

1. Remove exhaust manifolds (9430) as outlined.

1. Loosen rocker arm seat retaining bolts enough to allow rocker arm (6564) to be lifted off the push rod (6565) and rotate to one side.

1. Remove push rods . Identify position of each push rod . Push rods should be installed in their original position during assembly.

1. Remove cylinder head retaining bolts and discard.

1. Remove cylinder heads .

1. Remove and discard old head gaskets (6051) .

Installation

1. NOTE: Lightly oil all bolts and stud bolt threads before installation except those specifying special sealant.
   Clean cylinder head, intake manifold , valve cover (6582) and head gasket surfaces. If cylinder head was removed for head gasket replacement, check flatness and sealing areas for scratches of cylinder head and cylinder block gasket surfaces. Refer to Section 03-00 for procedure.
2. Position new head gaskets onto cylinder block (6010) using cylinder head to block dowels (6A008) for alignment.
   
   Head Gasket
   
   
   
   
   
3. Position cylinder heads onto cylinder block .
4. CAUTION: Always use new cylinder head bolts to ensure a leak-tight assembly. Torque retention with used bolts can vary, which may result in coolant or compression leakage at the cylinder head mating surface area.
   -ft).
   
5. For 3.8L non-SC engine, tighten cylinder head retaining bolts in numerical sequence in three steps as follows:
   1. 20 Nm (15 Lb-Ft)
   1. 40 Nm (29 Lb-Ft)
   1. 50 Nm (37 Lb-Ft)
6. CAUTION: Do not loosen all of the bolts at the same time, only work on one bolt at a time or possible damage to engine or leakage may occur.
   In sequence, loosen retaining bolts two to three revolutions and retighten bolts one at a time in the following manner:
   1. Long bolts:
      • 15-25 Nm (11-18 lb-ft).
      • Tighten bolt an additional 85-95 degrees.
      • Go to next bolt in sequence.
   1. Short bolts:
      • 10-20 Nm (7-15 lb-ft).
      • Tighten bolt an additional 85-95 degrees.
      • Go to next bolt in sequence.
      
      
      
      
      
      Item Part Number Description 1 6010 Cylinder Block 2 - Locating Pin (2 Req'd) 3 N802515-S Cylinder Head Bolt (4 Req'd Each Side) 4 6049 Cylinder Head 5 N802516-S Cylinder Head Bolt (4 Req'd Each Side) 6 6A008 Cylinder Head to Block Dowel
7. NOTE: If original valve train components are being installed, a valve clearance check is not required. If a component has been replaced, perform a valve clearance check as outlined.
   Dip each push rod end in Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford Specification ESR-M99C80-A and install push rods in their original position.
8. For each valve, rotate crankshaft (6303) until valve tappet (6500) rests on the heel (base circle) of the camshaft lobe, before tightening rocker arm seat retaining bolts to 7-15 Nm (5-11 lb-ft) maximum.
9. Lubricate all rocker arms with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford Specification ESR-M99C80-A. Final-tighten the rocker arm seat bolts to 30-40 Nm (22-30 lb-ft). For final tightening, camshaft (6250) may be in any position.
   
10. Install exhaust manifolds as outlined.
11. Install lower intake manifold as outlined.
12. Install fuel injection supply manifold .
13. Position valve cover and new valve cover gasket (6584) on cylinder head and install retaining bolts. Note location of ignition wire routing clip stud bolts. Tighten retaining bolts to 9-12 Nm (7-9 lb-ft).
14. Install upper intake manifold .Install spark plugs (12405) , if removed.
15. Connect ignition wires to the spark plugs .
16. If LH cylinder head is being installed, perform the following:
    1. Install oil filler cap.
    1. Install generator/power steering pump mounting bracket.
    1. Install generator .
    1. Install main accessory drive belt tensioner .
    1. Install power steering pump (3A674) .
1. Install power steering pump support bracket.If RH cylinder head is being installed, perform the following:
17. 1. Install positive crankcase ventilation valve .
    1. If equipped with A/C, install A/C compressor mounting brackets (2882) and A/C compressor .
18. Install drive belt and tighten to specification.
19. Connect battery ground cable .
20. Install air cleaner outlet tube.

Exactly what is the wrong? Need the part? Need to know torque adjust or porcedure to take off?

For 1994 Pontiac Grand Am 3.1L SFI OHV 6cyl check this procedure for Intake Manifold...
(see Figure 14)
The 3.1L engine is equipped with upper and lower intake manifolds. The upper intake manifold is also known as the intake manifold plenum.

CAUTION The fuel system is under pressure and must be properly relieved before disconnecting the fuel lines. Failure to properly relieve the fuel system pressure can lead to personal injury and component damage.

1. Relieve the fuel system pressure.
2. Disconnect the negative battery cable.
3. Remove top half of the air cleaner assembly and throttle body duct.
4. Drain and recycle the engine coolant.
5. Disconnect the EGR pipe from exhaust manifold.
6. Remove the serpentine belt.
7. Remove the brake vacuum pipe at the intake plenum.
8. Disconnect the control cables from the throttle body and intake plenum mounting bracket.
9. Remove the power steering lines at the alternator bracket.
10. Remove the alternator.
11. Label and disconnect the ignition wires from the spark plugs and wire retainers on the intake plenum.
    
12. Remove the ignition assembly and the EVAP canister purge solenoid together.

Fig. 14: View of the intake manifold and related components

1. Disconnect the upper engine wiring harness connectors at the following components:
   Throttle Position Sensor (TPS) Idle Air Control (IAC) Fuel Injectors Coolant temperature sensor Manifold Absolute Pressure (MAP) sensor Camshaft Position (CMP) sensor
2. Tag and disconnect the vacuum lines from the following components:
   Vacuum modulator Fuel pressure regulator PCV valve
3. Disconnect the MAP sensor from upper intake manifold.
4. Remove the upper intake plenum mounting bolts and lift off the plenum.
5. Disconnect the fuel lines from the fuel rail and bracket.
6. Install engine support fixture special tool J 28467-A or an equivalent.
7. Remove the right side engine mount.
8. Remove the power steering mounting bolts and support the pump out of the way without disconnecting the power steering lines.
9. Disconnect the coolant inlet pipe from the outlet housing.
10. Remove the coolant bypass hose from the water pump and the cylinder head.
11. Disconnect the upper radiator hose at thermostat housing.
12. Remove the thermostat housing.
13. Remove both rocker arm covers.
14. Remove the lower intake manifold bolts. Make sure the washers on the four center bolts are installed in their original locations.
    

When removing the valve train components they should be kept in order for installation the original locations.

1. Remove the rocker arm retaining nuts or bolts and extract the rocker arms and pushrods.
2. Remove the intake manifold from the engine. Remove and discard the gasket.
3. Using a suitable scraper, clean gasket material from all mating surfaces. Remove all excess RTV sealant from front and rear ridges of cylinder block
   

To install:

1. Place a 0.12 inch (3mm) bead of RTV, on each ridge, where the front and rear of the intake manifold contact the block.
2. Using a new gasket, place the intake manifold on the engine.
3. Install the pushrods in their original locations. Coat the pushrods with prelube.

The intake pushrods are marked yellow (5 3 /4 inch long) and the exhaust are green (6 inches long). Make sure the pushrods are properly seated in the valve lifters and rocker arms.

1. Position the rocker arms in there original locations and tighten to specifications. Refer to the procedure earlier in this section.
2. Install lower the intake manifold attaching bolts. Apply sealant 12345739 (or equivalent thread locking compound) to the threads of bolts. Tighten the vertical bolts first then the diagonal bolts to 115 inch lbs. (13 Nm).
3. Install the front rocker arm cover.
4. Install the thermostat housing.
5. Connect the upper radiator hose to the thermostat housing.
6. Fasten the coolant inlet pipe to thermostat housing.
7. Connect coolant bypass pipe at the water pump and cylinder head.
8. Install the power steering pump in the mounting bracket.
9. Loosely install the serpentine belt.
10. Connect the right side engine mount.
11. Remove the special engine support tool.
12. Fasten the fuel lines to fuel rail and bracket.
13. Install the upper intake manifold and tighten the mounting bolts to 18 ft. lbs. (25 Nm).
14. Install the MAP sensor.
15. Connect the upper engine wiring harness connectors to the related components removed earlier.
16. Connect the vacuum lines to the PCV, vacuum modulator and fuel pressure regulator.
17. Install the EVAP canister purge solenoid and ignition assembly.
18. Install the alternator assembly.
19. Connect the power steering line to the alternator bracket.
20. Install the serpentine belt.
21. Connect the spark plug wires to the spark plugs and intake plenum wire retainer.
22. Install the EGR pipe to the exhaust manifold.
23. Attach the control cables to the throttle body lever and upper intake plenum mounting bracket.
24. Install air intake assembly and top half of the air cleaner assembly.
25. Install the brake vacuum pipe.
26. Fill the cooling system.
27. Connect the negative battery cable, then start the vehicle and verify that there are no leaks.

For PARTS REPLACEMENT check in THIS LINK: carpartswholesale.com

Hope helps.

You will need a few things to do this job. Lets start with the auto parts store- new thermostat(make sure it comes with the gasket), gasket sealant, coolant, (if your hose are 3 years or more)new hoses, hose clamps. now for the tools, scraper, ratchet, extension, and metric sockets, flat tip screw driver, and maybe pliers. got it, good, lets start. follow the top hose to the cap( or thermostat housing cover), on the air intake, and remove the hose. now on the cap, you will see 2 bolts(one on each side), remove the bolts and save the bolts. gently pry up the cap, and scrape it clean(to the metal), removing the old gasket, and gasket sealant. now remove the old thermostat, and clean that also(down to metal also) to remove the gasket and sealant. apply gasket sealant and install the new thermostat. place new gasket, and apply gasket sealant to the cap. replace the cap, and bolt back down(do not over tighten, the cap will break) reconnect the hose. allow 30 minutes to allow the sealant to set up. start the car and let it warm up. check for leaks. no leaks, great. allow to cool, and replace any coolant needed. Hope this helps

Cylinder Head Removal & Installation 5.7L Engine To Remove:

1. Disconnect the negative battery cable.
2. Drain the engine coolant.
3. Remove the air cleaner assembly.
4. Remove the upper radiator hose.
5. Remove both heater hoses.
6. Disconnect spark plug wires at distributor cap.
7. Remove distributor cap.
8. Remove the coolant bypass hose from the water pump.
9. Remove the drive belt. NOTE: It is not necessary to evacuate the A/C refrigerant.
   
10. Remove the A/C compressor from the mounting bracket and set it aside.
11. Remove the wiring bracket from the rear of the cylinder head.
12. Disconnect the accessory bracket and slide forward.
13. Remove the upper and lower intake manifold.
14. Remove the exhaust manifolds.
15. Remove the valve rocker arms and pushrods.
16. Remove the power steering pump pulley.
17. Disconnect the electrical connector from the power steering pump.
18. Remove nuts attaching the power steering pump to the engine.
19. Remove power steering pump mounting bracket bolts and nut.
20. Slide power steering pump/bracket assembly forward and remove stud.
21. Set power steering pump/bracket assembly aside.
22. Disconnect the wiring bracket from rear of the right cylinder head.
23. Remove the generator.
24. Remove the oil indicator tube bracket bolt.
25. Remove the generator mounting bracket.
26. Remove the sixteen cylinder head bolts.
27. Remove cylinder heads and gaskets.
28. Clean all sealing surfaces.

To Install:
Right Side NOTE: Clean all dirt, debris, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to components.
NOTE: Do not use any type of sealant on the cylinder head gasket (unless specified).

1. Clean the cylinder head bolt holes with a thread chaser and compressed air.
2. Check the cylinder head locating pins for proper installation.
3. Place a new cylinder head gasket over the engine block dowel pins.
4. Install the cylinder head to the engine block.
5. Apply sealant (GM P/N 12346004 or equivalent) to cylinder head bolt threads.
6. Install the cylinder head bolts.
   
   
7. Tighten the cylinder head bolts in sequence on the first pass.
   • Torque to: 22 ft. lbs. (30 Nm)
8. Using a torque angle meter, tighten the long bolts (1, 2, 5, 6, 9, 10 and 13) on the second pass in sequence to 75°.
9. Using a torque angle meter, tighten the medium bolts (14 and 17) on the second pass in sequence to 65°.
10. Using a torque angle meter, tighten the short bolts (3, 4, 7, 8, 11, 12, 15 and 16) on the second pass in sequence to 55°.
11. Install the valve rocker arms and pushrods.
12. Install the generator mounting bracket stud.
    • Torque to: 15 ft. lbs. (20 Nm)
13. Loosely assemble the generator mounting bracket over the stud.
14. Install all nuts and bolts finger tight.
    • Torque to: 30 ft. lbs. (41 Nm)
15. Install the generator.
16. Install the oil indicator tube bracket bolt.
17. Install the exhaust manifold.
18. Install the lower intake manifold.
19. Install the valve rocker arm covers.
20. Install the wiring bracket to the rear of the cylinder head.
21. Connect the accessory bracket.
22. Install the A/C compressor.
23. Install the drive belt.
24. Install the distributor cap.
25. Connect the spark plug wires to the distributor cap.
26. Install both heater hoses.
27. Install the upper radiator hose.
28. Install the air cleaner assembly.
29. Refill the engine coolant.
30. Connect the negative battery cable.

Left Side To Install:
NOTE: Clean all dirt, debris, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to components.
NOTE: Do not use any type of sealant on the cylinder head gasket (unless specified).
NOTE: Clean all dirt, debris, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to components.
NOTE: Do not use any type of sealant on the cylinder head gasket (unless specified).

1. Clean the cylinder head bolt holes with a thread chaser and compressed air.
2. Check the cylinder head locating pins for proper installation.
3. Place a new cylinder head gasket over the engine block dowel pins.
4. Install the cylinder head to the engine block.
5. Apply sealant (GM P/N 12346004 or equivalent) to cylinder head bolt threads.
6. Install the cylinder head bolts.
   
   
7. Tighten the cylinder head bolts in sequence on the first pass.
   • Torque to: 22 ft. lbs. (30 Nm)
8. Using a torque angle meter, tighten the long bolts (1, 2, 5, 6, 9, 10 and 13) on the second pass in sequence to 75°.
9. Using a torque angle meter, tighten the medium bolts (14 and 17) on the second pass in sequence to 65°.
10. Using a torque angle meter, tighten the short bolts (3, 4, 7, 8, 11, 12, 15 and 16) on the second pass in sequence to 55°.
11. Install the valve rocker arms and pushrods.
12. Install the power steering pump mounting bracket stud.
    • Torque to: 15 ft. lbs. (20 Nm)
13. Loosely assemble the mounting bracket over the stud.
14. Install all nuts and bolts finger tight.
    • Torque to: 30 ft. lbs. (41 Nm)
15. Install the power steering pump pulley.
16. Connect the electrical connector to the power steering pump.
17. Install the exhaust manifold.
18. Install the lower intake manifold.
19. Install the valve rocker arm covers.
20. Install the wiring bracket to the rear of the cylinder head.
21. Connect the accessory bracket.
22. Install the A/C compressor.
23. Install the drive belt.
24. Install the distributor cap.
25. Connect the spark plug wires to the distributor cap.
26. Install both heater hoses.
27. Install the upper radiator hose.
28. Install the air cleaner assembly.
29. Refill the engine coolant.
30. Connect the negative battery cable.

Left side:

To install:

1. Lubricate all the valvetrain components with engine oil.
   
2. Install or connect the following:
   
   • Pushrods and the rocker arms and tighten the bolts to 14 ft. lbs. (19 Nm) plus 30 degrees
     
   • Rocker arm cover using a new gasket and tighten the rocker cover bolts to 89 inch lbs. (10 Nm)
     
   • PCV valve to the rocker arm cover
     
   • Coolant tube with the thermostat bypass hose and tighten the bolt to 98 inch lbs. (11 Nm) and the nut to 18 ft. lbs. (25 Nm)
     
   • AIR check valve pipe and torque the adapters to 22 ft. lbs. (30 Nm)
     
   • Engine mount strut and torque the bolt to 35 ft. lbs. (48 Nm)
     
   • Spark plug wires
     
   • Negative battery cable
     

Right side:

To install:

1. Lubricate all the valve train components with engine oil.
   
2. Install or connect the following:
   
   • Pushrods and the rocker arms and tighten the bolts to 14 ft. lbs. (19 Nm) plus 30 degrees
     
   • Rocker arm cover using a new gasket and tighten the rocker cover bolts to 89 inch lbs. (10 Nm)
     
   • Power brake booster vacuum pipe to the plenum
     
   • EVAP solenoid and ignition coil assembly
     
   • Spark plug wires
     
   • Alternator bracket and torque the bolts to 37 ft. lbs. (50 Nm)
     
   • Alternator and torque the bolts to 37 ft. lbs. (50 Nm)
     
   • Accessory drive belt
     
   • Negative battery cable
     
3. Start the vehicle and verify no leaks.
   

The valve covers installed on the 3.0L engine incorporate integral (built in) gaskets which should last the life of the vehicle. Replacement gaskets are available if required.

1. Disconnect the negative battery cable. Disconnect the ignition wires from the spark plugs, but leave them attached to their wire looms.
2. Remove the ignition wire separators from the rocker arm cover attaching bolt studs with the wires attached, then lay the wires out of the way.
3. If the left hand cover is being removed, remove the throttle body assembly, the PCV valve and fuel injector harness stand-offs. If the right hand cover is being removed, remove the engine harness connectors, fuel injector harness stand-offs and air cleaner closure hose from the oil fill adapter.
4. Using caution, slide a sharp thin blade knife between the cylinder head gasket surface and the valve cover gasket at the four RTV junctions. CUT ONLY THE RTV SEALER AND AVOID CUTTING THE INTEGRAL GASKET.
5. Remove the integral gasket from the valve cover gasket channel. Note bolt/stud fasteners locations before removing gasket for correct installation. Clean gasket channel and remove any traces of RTV sealant.

To install:

1. Align fastener holes, lay new gasket onto channel and install by hand. Install gasket to each fastener, seat fastener against cover and at the same time roll gasket around fastener collar. If installed correctly all fasteners will be secured by gasket and not fall out.
2. Install valve cover to the engine, lightly oil all bolts and stud threads. Apply a bead of RTV sealant at the cylinder head to intake manifold rail step (two places per rail).
3. Place the valve cover on the cylinder head and install attaching bolts and studs. Tighten the attaching bolts to specifications.

Fig. Fig. 3: Rocker arm cover installation on 3.0L engines

1. Install all remaining components in reverse order of removal procedure. Connect the ignition wires to the spark plugs and reconnect the negative battery cable. Start the engine and run to normal operating temperature, then check for oil and vacuum leaks.

Use a film of gasket sealant on both sides of the new gasket when you replace it. When installing the cover, make sure there isn't any wiring or anything that could get caught under it.