service
Need 3/8 drive socket set and a Torque wrench.
Intake gasket set $35.00. Use "The Right Stuff Gasket Sealer" Made by Permatex. Available from Pep Boys and Advance Auto Parts. Use it on the back and front where the intake manifold seals to the block. Use brake cleaner and make sure all surfaces are oil free.
Discard the rubber ones in the kit.
Purchase Felpro rubber type valve cover gaskets available from Autozone. No sealer is needed $30.00 1 day job for intake and valve cover gaskets.
If the trans. leak is on the passenger side, Tranny O ring $10.00 It most likely is from the Dipstick tube. If part stores don't have the seal, go to a trans. shop. 1 hr. labor to install. If your Vette is a 96 you have the 4L60-E tans.
Serpentine belt $25.00 .25 hr labor to install.
Need 1/2 breaker bar to release tension from the belt tensioner.
Prestone coolant flush kit. $5.00 .5 hr. to install. Allows you to use your garden hose to flush the system.
Tranny flush? Could cause problems on a high mileage car. The factory transmission pan has no drain plug so the complete pan needs to be dropped if they change the filter, a new gasket would need to be installed. Not difficult, but messy. About a dozen bolts to remove the pan. The filter pulls out, make sure the O ring seal on the filter tube comes out with the filter.
FelPro rubber Pan gasket from Autozone $3.00. Trans filter $20.00.
Discard the gasket that comes with the kit. They are usually poor quality and will leak.
I'd say fix it yourself. Take your time and do it right.
Last edited by Hooked on Vettes; Mar 25, 2005 at 12:39 PM.
The intake gasket/valve cover gasket is very easy:
1. remove (-) terminal battery connection
2. Take off plastic fuel rail covers.
3. take off intake plumbing (plastic/rubber tube going from air filter to TB).
4. drain coolant from radiator.
5. Open up fuel cap in back (or you will spill more gas as you disconnect the gas lines)
6. Disconnect the gas lines from the fuel rail (you need a $5.00 gas line tool to do this.
7. Unbolt and pull the fuel rail (also disconnect sockets from injectors).
8. disconnect the coolant lines from the Throttle Body
9. Unbolt any accessory brackets that go into the intake manifold.
10. Undo the serpentine belt.
11. Remove the alternator, and upper alternator brackets (to get at the valve covers).
12. Remove the valve covers.
13. Remove the intake manifold bolts.
14. Make sure all electronic connections to the intake manifold area are disconnected.
15. Pull off the intake manifold.
16. use a gasket scraper to get ALL of the old gasket material off.
17. Install the intake manifold gaskets (and use RTV for the flat parts in the "valley"
18-end- reassemble everything.
I think that is everything. There may be a thing or two in the way that you need to move, that I didnt mention, but it shouldnt be too bad.
You will need a good socket set, star wrench set (For the alternator bolts), and the fuel line tool.
I have done it several times, and have it down to ~1.5-2 hours from start to finish, but if it is your first time, give yourself a half a day. While you have the valve covers off, you might consider some 1.6RRs.. nice performance mod, and a good set is much less than what you save over having the dealer do the intake.
Also, while you have it all off, I would suggest new O-rings for your injectors, and if your Throttle Body is filthy, disassemble, clean it, and install new gaskets.
Just make sure when you're done, you have no extra/left over parts.

been there, done that. Had an extra little bracket laying around. Couldn't for the life of me, figure out where it went. Posted a picture on the forum, and within 10 minutes had it back in its home under the alternator..







