Gather your tools and materials, including a lower intake manifold gasket, gasket sealant, a ratchet and socket set, a pry bar, and a torque wrench.
Disconnect the battery
Open the hood of your car and disconnect the negative battery cable to prevent electrical shock while you work.
Drain the coolant:
- Locate the drain plug on the radiator and place a drain pan underneath it.
- Open the drain plug and allow the coolant to drain completely.
Remove the air intake assembly:
- Disconnect the air intake hose from the throttle body.
- Remove the bolts that secure the air intake assembly and remove the assembly.
Remove the throttle body:
- Disconnect the throttle cable and the electrical connectors from the throttle body.
- Remove the bolts that secure the throttle body and remove the throttle body.
Remove the upper intake manifold:
- Remove the bolts that secure the upper intake manifold to the lower intake manifold.
- Carefully lift the upper intake manifold and set it aside.
Clean the mating surfaces:
- Clean the mating surfaces of the lower intake manifold and cylinder head to remove any old gasket material or dirt.
Apply gasket sealant:
- Apply a thin bead of gasket sealant to the mating surface of the lower intake manifold.
Install the lower intake manifold gasket:
- Place the new lower intake manifold gasket in position on the lower intake manifold.
Install the upper intake manifold:
- Carefully lower the upper intake manifold into position and align the bolt holes.
- Install the bolts and tighten them gradually and evenly to the specified torque.
Reinstall the throttle body:
- Position the throttle body and align the bolt holes.
- Install the bolts and tighten them to the specified torque.
Reconnect the throttle cable and electrical connectors.
Reinstall the air intake assembly:
- Position the air intake assembly and align the bolt holes.
- Install the bolts and tighten them to the specified torque.
Reconnect the air intake hose to the throttle body.
Reinstall the drained coolant:
- Close the drain plug on the radiator and refill it with the proper amount and type of coolant.
Reconnect the battery:
- Reconnect the negative battery cable to the battery.
Double-check all connections and ensure everything is secure.
Start your vehicle and let it run for a few minutes to check for any leaks.
These are the general steps for installing a lower intake manifold gasket on a 2002 Chevy Malibu 3.1L. Keep in mind that some details may vary, and it's important to refer to the vehicle's specific repair manual for exact instructions.
