I would try the GM dealer first; chances are they're a "dealer item only". You'll need upper (plenum) and lower intake gaskets, new bolts, valve cover gaskets, and a new o-ring for the oil pump drive shaft.

Edit: And replace the fuel injector o-rings as well; better safe than sorry..

And I hear you should replace the injector o-rings while you've got the fuel rail torn off.

OK...Here's the Dorman kit that looks like it has the upper and lower gaskets, valve cover gaskets, o-rings and bolts too. Has anyone used this kit before? Is it ok?

http://www.partsamerica.com/ProductDetail.aspx?MfrCode=DOR&MfrPartNumber=615205&PartType=102&PTSet=A

If not, does anyone have a link to a gasket kit that has all the pieces and the updated bolts?

Edit: I called the dealer and the LIM gaskets/bolts alone are $63. $20 each for valve cover gaskets. Ouch.

That kit should work just fine; nice to see Dorman released an updated reseal kit...when I worked on these a couple of years ago, they were only available from the dealer. I would get a set of injector o-rings as well.

If you're going to tackle this yourself, remember to keep the rockers and pushrods in order, and don't use the windshield cowl as a "tool shelf". I once had a 3.1L GP get towed in from another repair shop, because it wouldn't start and run. Removed the lower intake and found a 1/4" drive socket sitting on one of the valves...

Are you talking about the fuel inlet and pressure regulator o-rings? Or are there o-rings for each individual fuel injector?

Edit: So you really do need to take the pushrods and rockers off to get those gaskets in?

The injectors each have an upper and lower o-ring. If you type in the part number(615-205)on Dorman\'s site, it tells you what's in the kit. The injector o-rings aren't included.

Here's the write up: LIM

Thanks a bunch!

I just ordered the Dorman kit. It won't be in for a few days so that'll give me time to break down, clean and prepare the manifold. The injector o-rings don't seem to be that hard to get so I should be able to pick those up at the parts house.

Another question: How do I relieve the fuel pressure so I don't get gas spewed all over me when I remove the fuel rail connections? Where is the "test port" that the link mentions?

The test port is on the fuel rail; it looks like a Schrader valve with a cap on it: Relieving Fuel System Pressure (Different engine, but procedure is similar)
One more thing: It's a good idea to replace the Engine Coolant Temp Sensor (TU178) while the engine's apart; you can see it in this pic:

I wish I'd seen this sooner... H.R.H. King Lerxst, you should have went to Autozone or whoever and got the FelPro 'Problem Solver' intake kit for the 3100. It's around $80, but it has all your gaskets and metal lower intake gaskets. It is as good or better than the GM stuff. MS98003T:


You don't need new intake bolts unless they're TTY. I don't believe they are. You have to remove the pushrods because GM designed the pushrod guides into the intake gasket. Go figure. This necessitates the removal of valves covers and rockers.

Blackarrow: Yeah, that sensor has gunk all around it. Was definitely going to replace that guy while the motor was torn apart.

RooK: I saw that one as well but I went with the one that contained the newer bolts b/c of the update that went out from GM. I figured if it had the new bolts, that it had the newer gaskets as well.

Now I'm not a design engineer, but on the surface it seems pretty stupid to have the pushrod guides built into the gasket. But that's just me.

Thanks to everyone for all the good info. I'll post an after-action report if anyone's interested. I've never tackled anything this serious by myself before. Wish me luck!

Thanks again everyone!
Lerxst

Alright, what's the trick to disconnecting the fuel rail inlet? I've got it unscrewed but it doesn't want to come out.

The fuel pressure regulator popped right out with minimal force but the other one is being stubborn.

Any tricks? Or is it just a PITA to take out?

guaranteed way to remove the rail inlet? Hook one end of a rope to the inlet, and the other to the bumper of a tow truck.

OK...I have a tow truck, no problem.

How much of a PITA is it to get it BACK IN?

LOL. depends on how badly everything is torn up...duh! lol.

Sorry for thread jacking. Couldnt resist.

LOL @ Richard!

When I took my fuel rails out, just releaved preasure, squeezed tabs of fuel lines and wiggled them off, and unbolted the fuel rail and wiggled that off, and the injectors came with.