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-pull drain plug
-disconnect lower radiator hose and *inspect for replacement if needed
-disconnect upper hose *inspect
-remove T-stat and re install housing with t-stat removed *inspect
-flush with hose and or radiator flush product from top hose thru engine and top thru radiator....keep this up until all clean.
-install T-stat and reconnect hoses...open air bleed valves at heater core and Tstat housing also keep radiator cap off.
-turn the heater to heat and fan to low or medium
-keep filling the radiator as it sucks in the extra coolent. then cap the radiator and cap the heater core bleed screw
-once you hear your fans kick in, that is a good sign that your T-stat probably has opend, now you can finish bleeding the air from your bleed screw at the T-stat housing. once you stop seeing bubbles you are good. tighten and let the car get to temp check again aprox 5 min after at temp to be sure. then test drive and check one last time... and then you are GOOD.
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Common Problems:
-Intake gasket leaks. These cars especially the 3.4 DOHC have common leaks in the lower intake manifold gasket. Many of GM V6's have this problem. Due to the complex intake manifold, this problem is more frequent with the DOHC. Buy the new gasket set from GM. They have new sets that are more resistent to failure. Also, this engine has a very unfortunate problem with leaky oil pump o-ring seals. The o-ring in below a pannel under the lower intake manifold. It is a good idea to change it when you do your intake gaskets, or else you will do your gaskets twice.
To do this you will need:
-Metric/ Std sockets and extentions
-Large Pliers
-Coolent, carb/intake cleaner
-New PCV valve
-Towel or clean rags to block intake.
-Gasket set these are rather inexpensive from GM and the GM parts are better quality. Trust me you only want to do this once.
[intermediate arm to upper manifold, upper manifold to lower, lower to the heads, and the oil pump o-ring]
-Begin by removing the engine cover.
-Loosen and remove the bolts that hold the intermediate arm to the upper intake manifold.
-Remove the bolts that hold the upper intake manifold to the lower manifold 7 bolts 10mm.
-Disconnect the Vacume lines that go to the fuel regulators.
-Unplug the PCV and either clean with carb cleaner or replace with a new one.
-Unscrew and perge the fuel rail then disconect the two fuel lines that go to the fuel pressure regulator.
-Remove the coolent pipe and the pipes for the heater core.
-Unbolt the lower intake manifold. There are about 12 (10mm) bolts that hold it on.
-Once removed, clean all gasket surfaces before reinstalling.
-To replace the oil pump drive o-ring, remove the bolt that holds the little cover that is to the right (drv side) of the center of the engine.
-When reinstalling, follow torque specs or you run the risk of stripping your intake bolts. The intake bolts need no more then 14 ft-lbs. Make sure you start with the inner bolts and work out in a back an forth path from side to side making an expanding X to distribute the pressure and not toe bind the gaskets.
-Assembly is reverse of removal.
-Timing Belt. This is very serious. many people dont inspect it and it leads to failure. i would only give the belt about 60K before replacing it. yes it is expensive to replace, but it is better then replacing the belt, valves, and cylinder heads! Easy to inspect just pop the cover on the front side and look at the belt condition.
-Transimission! Trany's are the weak link in these cars. Do NOT fall behind on maintaince. becarful with used cars that dont have a paper work trail for them. If properly maintained and cared for they are great. but still they cant take big jumps in power with out upgrading.
Possible Hazard to other GM W-body'd cars
In the process of installing my FWI, I noticed that the primary ground wire for the battery was never secured properly. It was alowed to hang loose and rub against the AC dryer. This rubbing managed to eat away almost half the wire and some of the AC fitting. If this were to fail it would be difficult to track down. Please refrence my photos and check your W-body for similar problems.
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