The GM 4.2L LL8 Engine Intake Manifold uses unique, Low Torque "Trapped" Fasteners requiring a MAX of only 89 Inch Pounds because they bottom out and only serve to squash what would ordinarily be "new and plump" Rubber "O" Ring Style Gaskets in Three Sets shaped like sideways #8s along the interface of the Intake Manifold Flange.
Due to the 'pendulum' like action of the heavy Throttle Body being on one side, counter-balanced by the heavy PCM diagonally on the other... Engine and Body Vibrations will cause the Intake Manifold to rock back and forth, making the "O" Ring Style Gaskets
flatten out over time and allow unmetered Air to by-pass the PCM Engine Management System (The LL8 Motor is an Air Weight-Flow dependent system NOT Fuel Dominant) and this can cause Random Engine Misfires.
On Early Model TBs & Envoys the upper Center-Most Fastener is hidden under a Small Rubber Elbow Hose connecting the Intake Plenum to a Port in the Aluminum Engine Head. Be careful not to damage that little fellow during its R&R.
The Fasteners located closest to the Engine Firewall have been the source for inventing New Swear Words due to the difficulty in accessing them with a Small 3/8" Ratchet, a Short Extension and Little Universal Adapter to wend its weary way around and on top of that small IM Bolt Head.
You could try carefully tightening up any possible loosened Fasteners along the IM Flange... but avoid freelancing with this action. The same kind of Fasteners apply to the Engine Head Valve Cover. Unlike the Old GM Valve Cover Cork Gaskets ...ALL of these Fasteners sport a Very Short Thread Line
(M6X1.00X12mm) that can bottom out suddenly and very easily get Snapped Right Off if they get Tightened TOO Aggressively.
If anyone has already tried this and you discover that the Fasteners remain in place... but "spin free" when being tightened...do not despair. There are two specific Threads addressing how to perform this repair:
I have a 2003 Trailblazer EXT with 209,000 miles on it. I have changed the plugs twice every 100,000 miles with no problems. The other day it started running rough and was getting a flashing "Check Engine Soon" light. I ended up finding the #6 coil pack not seated on the plug because the hole...
gmtnation.com
Ok here's my issue. I am replacing and engine in my 2003 GMC Envoy and as I was switching over the intake manifold a bolt snapped off in the new engine block. I have drilled it out and just wondering how to get the broken bolt free from the manifold and if it's possible to replace the bolt...
gmtnation.com