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Finally decided to bite the bullet as fuel consumption got out of control,a/c would blow thru defroster vents on a slight hill, etc. Got the valve cover set from Autozone VS325 special order for $34.99. It has a heavier thicker gasket for the fuel manifold to lower intake. The plenum gaskets were 6 to a box only 3 needed. I got them at Advance for $3.99. they are rubber rings. I also bought a set of o-rings for the injectors. I have the plastic manifold. What makes the job awkward is that i have dual a/c and the hoses for the a/c and heat run across the top of the manifold to the rear a/c. The egr pipe from the intake is another hassle. I had to remove this tube before taking the intake out,also the air bypass, dfe sensor and vac solenoid. I used a small shop vac to remove the dirt etc around the intake. and valley area. The fuel manifold needs to be removed to clean the underside and top mating surfaces. The job has taken 3 hrs so far with 2 to go to finish.
look for corrosion pitting in the fuel injector holes in the fuel rail. can prevent proper sealing and cause fuel leaks. i just fought this demon.
i'd like 5 minutes with the engineer that layed out the Aero 4L engine compartment with the rear heater hoses and A/C hoses running over the top of the engine intake. He must have a hose fetish.
would have been easy to route along body firewall on one side of engine
have got to pull mine apart again. developed a leak in the heater hose outlet steel nipple to intake manifold.
Yes it makes you wonder what the engineers are thinking. Got it all back together. Engine now idles and sounds smoother and peppy. I found the fuel manifold gasket to be too thin from the factory and those plenum sealing o rings could be thicker.I can see how the vac leak can develop to the point that once the gasket fails the condition gets worse as time goes by..