Those Educated idiots who deigned that intake manifold , should be canned on the spot. My problem is that coolant tank return line stub broke off. There should have been a recall. It should have been just two bolts, not take the whole dang intake manifold off. To replace it. Thanks for the great video! Helped out quite a bit.
I did not remove the manifold. To remove the bulk of the plastic I used a putty knife bent 90 degrees and heated using a propane torch. I simply had to remove the valve body and lift bracket and vent tube to get access. Just putting this out there as an option. Cheers.
That seems to be a less invasive way to cut the manifold, than using an oscillating tool. I only took the long way to show manifold removal and gasket replacement.
Thank you so much for posting this video!! I have a 2002 Saturn Sl2 with this issue & the part was delivered today!! Same supplier! Also I appreciate how you showed how to troubleshoot the part to make it work!!
This makes me glad for having an SOHC. I'm doing the hose there. The hose pops down from the intake and I had to cut off the origional compression clamp with a dremel for lack of space (and bad clamp alignment) and an unwillingness to remove the manifold. Next session is going to get me a face full of coolant when I remove the other side from underneath. It's going to be a fun time getting a new clamp put back on, but at least I'll be able to align it better so I can get to it in the future, if needed.
This is a great install video. Even the manufacturer video for the kit was good. Kinda confusing. This gives me a good clear idea of what needs done. Thanks man!!
Great video. My 2001 sprang a leak also this week. Looks like the seam blew out on mine where you were thinking you had a hair line crack. Mine has a huge crack in it. Good info. Thanks!!
Cool video. I did mine a few years back but i left the intake in the car and i cut the plastic with a multi tool and it worked perfectly. Didnt seem right to take it all apart like that. Also i didnt use the doorman i went with another company and never had any leaks but also i paid more money.
+disabled vet There was one coolant pipe mentioned in a forum I'm part of but it seems like the site for this machined part has gone dead. Would have used it but the Dorman part was the only other option I could find apart from replacing the whole intake manifold. Also, too nerve-wracking for me to cut the intake with it still on but knew it could be done! Thanks for watching!
I used one of these kits 4 years ago, but I used the original kit made by CarSaturn. I did have a similar problem making it seal on the engine. I had to remove it, and put RTV silicone on both sides of the gasket. I haven't had issues since. I just got done changing the coolant on my '01 SC2 today, and the repkacement coolant stem still works fine!
What exactly product did you use (RTV silicon)? Can I use on that gasket RTV gasket maker silicon or it is smth else? Thank you for pointing out on a sealant on the gasket.
My son's 01 SW2 wagon had a similar problem. The overflow reservoir return nipple broke right off the intake manifold. The thought of taking half the engine apart seemed like a huge waste of time and energy for this particular vehicle. Not to mention the cost of replacing the manifold 😖 Instead I rerouted the return hose into a T I spliced into the 3/4 inch heater hose. Then I used a small soldering iron to melt the hole closed where the nipple broke. After researching different types of apoxys, it seemed safer to melt the plastic onto itself. Many apoxys weaken the plastic over time. It Seems to be holding up so far. I'll update with any issues if there are any. I also changed the thermostat for peace of mind. Anyone else notice these little cars use more oil than gasoline? 😂
Wish they did. The Felpro gasket I used was in the two pieces almost as if they new about the issue. After getting through the problems though, this was the cheapest way to fix it.
well on all these engines before 2000 the intake was metal but for the 2000 model year GM got involved and made them change it plastic to cut costs. a lot of engines have coolant in the intake but is usually because its where the thermostat is. on this engine i think that hose comes after the heater core.
why not stick some fine grit sandpaper onto a flat table and sand that new part flat. also use some gasket sealant. I've see old school guys flatten a whole cylinder head that way!
So did you put the original long stud into the previously empty hole @11:30 and left the new stud in the outer left side? I think Grainger is kind of place where they can have the right stud. Thank you so much for pointing out on the problem w/the surface of the aftermarket part. I'm expecting that part and of course to check on the smoothness of the surface. Then I'll check w/Grainger for the same, but longer studs. The coming part is Dorman and people complain that their gaskets are thin, what also can cause the issue. I even don't know, whatever appealing it looks to improve the original Intake w/better aftermarket metal part, but maybe just better to buy the whole new Manifold. I'll see. I'll also check around if you can go somewhere to machine that bottom. Thank you very much again. Update: I received the part today and it is wobbling on the smooth table as predicted. Maybe not that much, but it sure does. Looks like some wavy parts on the bottom from painting. 🧐Now I think what approach to take to smoothen it and what gasket maker to apply on both sides of the Dorman Gasket as recommended by one viewer in comments.
I sanded until I could see even coverage across the entire surface and it stood up without any wobble. You can also go by shining a light from behind. If none peaks through while mating surface is stood on a flat surface, then it should be good.
I had to buy this Dorman part and had to sand it too because it was not flat. I did it to the point of stripping all the paint and it was still wobbling around. Were yours like this too after sa nding?
Yes, I sanded down to bare metal on the pipe. It was a decent amount of material removal necessary to get it flat. Been working great so far after that! Just passed 240k miles with no leaks!
Not necessarily. If you found the replacement pipe was warped like mine. Sand it down flat and install. At this point this is the only inexpensive option available. Can also install a new intake manifold but I would consider that cost prohibitive unless you find a good one at the local salvage yard.
Those Educated idiots who deigned that intake manifold , should be canned on the spot. My problem is that coolant tank return line stub broke off. There should have been a recall. It should have been just two bolts, not take the whole dang intake manifold off. To replace it. Thanks for the great video! Helped out quite a bit.
I did not remove the manifold. To remove the bulk of the plastic I used a putty knife bent 90 degrees and heated using a propane torch. I simply had to remove the valve body and lift bracket and vent tube to get access. Just putting this out there as an option. Cheers.
That seems to be a less invasive way to cut the manifold, than using an oscillating tool. I only took the long way to show manifold removal and gasket replacement.
Thank you so much for posting this video!! I have a 2002 Saturn Sl2 with this issue & the part was delivered today!! Same supplier! Also I appreciate how you showed how to troubleshoot the part to make it work!!
This makes me glad for having an SOHC. I'm doing the hose there. The hose pops down from the intake and I had to cut off the origional compression clamp with a dremel for lack of space (and bad clamp alignment) and an unwillingness to remove the manifold. Next session is going to get me a face full of coolant when I remove the other side from underneath. It's going to be a fun time getting a new clamp put back on, but at least I'll be able to align it better so I can get to it in the future, if needed.
The part Dorman was copying is made by Carsaturn.com and is CNC machined. It's rock solid on the table. Same short crappy studs though.
I found that one too, but it appeared the website to order had been dormant for a while.
JungleKing007 i just ordered it came in the mail nice and quick
This is a great install video. Even the manufacturer video for the kit was good. Kinda confusing. This gives me a good clear idea of what needs done. Thanks man!!
Great video. My 2001 sprang a leak also this week. Looks like the seam blew out on mine where you were thinking you had a hair line crack. Mine has a huge crack in it. Good info. Thanks!!
Cool video. I did mine a few years back but i left the intake in the car and i cut the plastic with a multi tool and it worked perfectly. Didnt seem right to take it all apart like that. Also i didnt use the doorman i went with another company and never had any leaks but also i paid more money.
+disabled vet There was one coolant pipe mentioned in a forum I'm part of but it seems like the site for this machined part has gone dead. Would have used it but the Dorman part was the only other option I could find apart from replacing the whole intake manifold. Also, too nerve-wracking for me to cut the intake with it still on but knew it could be done! Thanks for watching!
Agree-maybe insering a metal sleeve and glue? Removing the IM is a lot of work.
if you want do any kind of the work, Permatex Gasket maker is a must. otherwise, it is a good chance to re-visit the job again.
Excellent Video. Bravo my friend. Your on the job!
I used one of these kits 4 years ago, but I used the original kit made by CarSaturn. I did have a similar problem making it seal on the engine. I had to remove it, and put RTV silicone on both sides of the gasket. I haven't had issues since. I just got done changing the coolant on my '01 SC2 today, and the repkacement coolant stem still works fine!
What exactly product did you use (RTV silicon)? Can I use on that gasket RTV gasket maker silicon or it is smth else? Thank you for pointing out on a sealant on the gasket.
My son's 01 SW2 wagon had a similar problem. The overflow reservoir return nipple broke right off the intake manifold. The thought of taking half the engine apart seemed like a huge waste of time and energy for this particular vehicle. Not to mention the cost of replacing the manifold 😖 Instead I rerouted the return hose into a T I spliced into the 3/4 inch heater hose. Then I used a small soldering iron to melt the hole closed where the nipple broke. After researching different types of apoxys, it seemed safer to melt the plastic onto itself. Many apoxys weaken the plastic over time. It Seems to be holding up so far. I'll update with any issues if there are any. I also changed the thermostat for peace of mind. Anyone else notice these little cars use more oil than gasoline? 😂
I was holding steady at 1 quart of oil every 1000 miles. Thanks for watching!
this video helped a lot, thanks man
seems like Saturn designed a flaw in that intake on purpose. The intake should of came in 2 pieces.i'm surprise the fix wasn't a new intake manifold.
Wish they did. The Felpro gasket I used was in the two pieces almost as if they new about the issue. After getting through the problems though, this was the cheapest way to fix it.
well on all these engines before 2000 the intake was metal but for the 2000 model year GM got involved and made them change it plastic to cut costs. a lot of engines have coolant in the intake but is usually because its where the thermostat is. on this engine i think that hose comes after the heater core.
why not stick some fine grit sandpaper onto a flat table and sand that new part flat. also use some gasket sealant. I've see old school guys flatten a whole cylinder head that way!
I did sand it down after finding the replacement was the same way.
How big of a difference did those Prothane TSM inserts make? Does the powertrain feel more solid?
Bit more vibration felt in the frame but the engine is solid. A little better response during quick acceleration.
Great video btw! thank you
So did you put the original long stud into the previously empty hole @11:30 and left the new stud in the outer left side? I think Grainger is kind of place where they can have the right stud. Thank you so much for pointing out on the problem w/the surface of the aftermarket part. I'm expecting that part and of course to check on the smoothness of the surface. Then I'll check w/Grainger for the same, but longer studs. The coming part is Dorman and people complain that their gaskets are thin, what also can cause the issue. I even don't know, whatever appealing it looks to improve the original Intake w/better aftermarket metal part, but maybe just better to buy the whole new Manifold. I'll see. I'll also check around if you can go somewhere to machine that bottom. Thank you very much again.
Update: I received the part today and it is wobbling on the smooth table as predicted. Maybe not that much, but it sure does. Looks like some wavy parts on the bottom from painting. 🧐Now I think what approach to take to smoothen it and what gasket maker to apply on both sides of the Dorman Gasket as recommended by one viewer in comments.
thanks for the video. just got my dorman 902-100 for my 2000 sw2. how long did you spend sanding? until no feeler gauge could go under? thanks
I sanded until I could see even coverage across the entire surface and it stood up without any wobble. You can also go by shining a light from behind. If none peaks through while mating surface is stood on a flat surface, then it should be good.
Thats Dorman for ya.
How much should a repair like this cost?
I had to buy this Dorman part and had to sand it too because it was not flat. I did it to the point of stripping all the paint and it was still wobbling around. Were yours like this too after sa
nding?
Yes, I sanded down to bare metal on the pipe. It was a decent amount of material removal necessary to get it flat. Been working great so far after that! Just passed 240k miles with no leaks!
@@jungleking007Channel So you were able to get it completely flat? Nice!
What if leak is at radiator?
So basically I'm screwed
Not necessarily. If you found the replacement pipe was warped like mine. Sand it down flat and install. At this point this is the only inexpensive option available. Can also install a new intake manifold but I would consider that cost prohibitive unless you find a good one at the local salvage yard.
Great video!These cars suck👎🏽 such a horrible design.