2000 gmc safari intake manifold removal

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Replacing Lower Intake Manifold Gaskets (w/pics)

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• Drain the coolant. Best done when engine is warm to keep the thermostat open for complete head draining. Remove the Thermostat goose neck and coolant lines leading from the LIM (Lower Intake Manifold)
• Disconnect the battery.
• Remove: Alternator, EGR valve, Coil pack, Throttle cables and brackets, Distributor (Note: Remember to mark position of the dist. housing to manifold and the position of the rotor).
• Loosen the A/C - Power Steering Pump aluminum mounting bracket, slide assembly forward toward fan shroud to clear the LIM.
• Remove and move aside the EGR exhaust feed pipe at the LIM.
• Remove the Brake Booster hose, PCV hose, etc...
• Remove fuel feed pipe from injectors and supply lines at firewall (watch those two O-rings that are at the firewall connection).
• Remove all electrical connectors from their terminations (MAP sensor, EVAP purge valve, Throttle body, etc...)
• Tie main wiring harness up and out of the way.
• Remove the eight LIM bolts. Gently remove the LIM as an assembly.
• Final torque, 11 lb./ft.

this should be a sticky considering the other s10 site has something like this  

Great Job. Man your engine is clean.  

I can tell you first hand, that a clean engine makes working on it much more of a pleasure. I Purple Power'ed it when I first got it and have worked hard to eliminate any oil leaks. One benefit to being a neat freak.  

Good write-up. I 2nd the sticky idea.  

I know it's old and dropped down the list, but the problem with so many stickies is that they clutter the top of the forum index. The mods really need to unstick the ones there, and create a "Helpful 4.3L Forum Threads" thread and stick it. The first post can be maintained to have links to all the good info threads out there, and that way, you don't clutter the top of the index, but retain a very easily accessible list of good help. But yes, this particular thread helped me a lot with mine. Going to make those guide pins now.  

98SS said: I Going to make those guide pins now. Click to expand...

Very good write up. Do you really need to Give the silicone 24 hours to fully cure before adding back the coolant and running the engine? I put lifters in my wifes Blazer this summer and I never waited. I am doing a intake gasket job on my truck this saturday. I just don't have time to wait for a day to drive it.  

yeah,i was just told that i might need a new intake gasket this morning.this is helping me out alot.  

The only suggestion I have is to make a cardboard template and poke holes for all of the bolts...zip ties for the nuts. Makes reassembly much easier. I didn't even have any left over parts when I did mine...:rotf: P.S.....remove the hood, and for heaven sakes...bring the dist to TDC and mark the damn thing...  

Rhotpursuit said: remove the hood, Click to expand...

Rhotpursuit said: and for heaven sakes...bring the dist to TDC and mark the damn thing... Click to expand...

I did this job over the weekend using only the instructions in this thread and didn't have any problems. I really didn't feel like springing for a repair manual for this truck. I figure the pictures in this thread are better than the manual anyway. If you take your oil cap off and you notice its full of water droplets but your oil isnt a milkshake yet you might want to consider doing this. I thought i just had the usual condensation in my motor from not driving it long enough. A week or so later my oil is a milkshake and theres coolent running down the backside of the motor and over the tranny and then it dawns on me whats happened. Mark your distributor and rotor well when you take it out its kinda tricky getting it back in and lined up even though I had marked it well. If your just trying to do from memory your going to get it wrong.  

yummycheese said: I did this job over the weekend using only the instructions in this thread and didn't have any problems. I really didn't feel like springing for a repair manual for this truck. I figure the pictures in this thread are better than the manual anyway. Click to expand...

yep,that was the worst part when i did mine last month.its a pain to get the dist. back just right took a few trys.but finally got it  

Sticky This x1000 Good info for people.  

I did mine a 98 blazer . Make sure you get a pulley puller for power steering pulley. So you can remove the bracket. I bought the intake gasket kit and i bought valve cover gaskets. I figured while it was a part why not. Also did the throttle body mod that remves the extra piece on the butterfly. Finish buttoning it up tomorrow and hope for the best. All and all not that bad with the right tools. Only thing i cant figure out how to get the pulley instlller to work. Thats why i stopped tonight. Any ideas?  

You don't need to remove the A/C bracket. The bolts behind that pulley can be accessed from underneath the truck. Loosen them and slide the bracket forward enough to get to the front LIM bolt. Ratchet wrenches would work best, but regular open ended wrenches would get it done also without having to screw with the pulley.  

Guess that was the problem didnt want to go underneath. Any idea on how to get the d**n screw to go into the hole to get it back on.  

If you rented a puller/installer, it should have instructions. One of those studs screws into the end of the pulley shaft.  

Excellent write-up, Bill! Thanks!  

anybody got an estimated cost on parts for this?, as well as how long it will take, half-a-day? longer? just trying to plan out time/money for this  

summit has a set from felpro, all the gaskets for the upper intake (manifold to head, orings for everything up top) for 49$. just ordered mine today  

You can get the same set locally and save the shipping...$50 at Schucks.  

Great write up! On all the intake gaskets I've done I haven't had a camera nearby to snap pics. Lol, also dread the job so I don't like to mull over it too much. Couple thing you need to add to the write up - before you get started, use and air hose or high water pressure to clean the topside of the engine so nothing drops into the lifter valley when you lift the intake. Also, get a roll of blue paper towels from your favorite parts house and use them on the intake runner of the heads to plug them before you clean the gasket mating surfaces to keep from dropping anything down into the cylnders. The blue paper towels are a little heavier than reg white, keeps from tearing and leaving bits of paper on the rough surfaces.  

I figured out the deal with the puller just junk in there. Rockauto.com has the set for around $31 plus ship. Takes about day if you have all your stuff together and no interuptions. She is up and running well. Took the extra piece off the thorttle body while it was apart. What a diffence that made. Not a bad job to do.  

Awesome write up. pics for extra points  

HELP!!!!! I replaced everything after doing this and it runs, however I tried driving down the block and got to the stop light and it was acting like it wanted to just cut out and die, it was kinda choppy feeling, so I put it in reverse and drove it back up to my building. the only thing I can think of is the distributor cap. when I removed it, I made sure to mark exactly where it sat, however when I pulled the distributor out I noticed a small "6" and an "8", I just figured I should put it back the way it came out, but now I'm not sure... any ideas? should it have gone on the 6 for V6, I think I remember seeing that somewhere. please help asap. I really need to get to school tomorrow.  

it should have gone in just as it came out. are u sure you got all of the wires hooked back up? did you turn the motor over at all while the distributor was out?  

samsonite, what year of truck? Double check the connections.  

thanks for the quick responses. no i didn't turn motor over, its an 2002 s-10 4wd. I may have an idea, as I was so quick and happy to get it back together without any missing peices so I started it up once it was all back together, but I think the sealant may not have cured. I am going to wait until tomorrow morning and then try again i guess. Is there any chance I screwed up the seal by starting it right away? i know I installed it right, guide pins (generic metal punches worked pretty well as guides) so it went straight down in, and i used the entire tube of sealant that came with the kit, and it was just enough for both sides, but i remember somebody mentioning waiting like 24 hours for it to dry.  

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Humane Society  of the Palouse

"helping those who cannot help themselves.", intake process.

Stray animals

If you have found a stray pet,  click here.   If you have found a stray pet after hours, click here.  

Stray dogs that are found in the city limits of Moscow are held for 10 days, while we search for an owner to claim them. Stray dogs that are found in Latah County are held for 6 days, while we search for an owner to claim them. Stray cats that are found either in city limits of Moscow or Latah County are held for 6 days, while we search for an owner to claim them. 

Upon arrival, HSoP staff immediately search for any identification (collar, ID tags, and microchips). If the animal has identification we contact the owners to alert them their animal is safe with us, and waiting to be picked up. If the animal does not have identification, or we cannot get a hold of the owners, we post a picture and description of the animal to our Facebook page.  

For information on fees when claiming your lost pet, click here.

If the animal is not claimed during the stray holding period, we begin the process of getting the animal ready for adoption. All animals adopted from HSoP are spayed/neutered, vaccinated, and microchipped prior to leaving the shelter. 

Owner Surrendered animals

Animals may be surrendered to HSoP for any number of reasons. HSoP does not accept aggressive animals, or animals with a known bite history. When an animal is surrendered to HSoP, we immediately start the process of getting them ready for adoption. If the animal is not already, we will spay/neuter, vaccinate, and microchip them.

For more information about owner surrenders, click here. 

*** HSoP is a no-kill shelter, which means we are limited admission intake. We do not euthanize animals for space. When our kennels are full we do have to place animals on our wait list to be brought into the shelter when space is available. Our wait list is dependent on our adoption rates. The quicker our animals find loving homes, the quicker we can bring new animals into HSoP. 

Dog Bite Quarantine Holds

For more information about dog bite quarantine holds at HSoP, click here.

HSoP does not have the capacity or safe-housing to take feral cats into our shelter.

For more information on feral cats, click here. 

Other Animals

HSoP does not have the space or safe-housing to take in birds or reptiles. HSoP does accept "pocket pets", such as ferrets, rabbits, rats, hamsters, and guinea pigs. We are limited on space for our small animal friends, so we do keep a wait list for animals to come in when we are full.

Read through our resource sheet for Found Pets .

Contact HSoP (208) 883-1166 to leave a "found" report, and see if an owner has contacted us missing this pet. ​​

Dogs found in Moscow and Latah County may be brought to the HSoP for holding until an owner is located.​

HSoP can also scan any found pet for a microchip. This service is also available at veterinary clinics.  

Contact your local police department or sheriff's office. An owner may have left a report with them.

    Moscow Police (208) 882-2677

    Sheriff's Office (208) 882-2216  

Make flyers in eye-catching colors with a photo and description of the found pet. Post flyers in your neighborhood, local shelters, veterinary hospitals, local websites, and grocery and feed stores. Even if the animal is in the shelter, these efforts will help the animal return home.  

Be aware that it is against City Code to post flyers on public property, such as telephone poles. ​   ​"The City of Moscow would like to remind citizens of the limits on posting signs or posters.  Per City Code Title 10 Section 1-22, posters or signs may not be attached on property that does not belong to the poster without first obtaining the consent of the property owner or their agent.  Also, posting signs on public property or right of way is prohibited.  The City does provide a free public bulletin board in Friendship Square for posting notices that is available to the public."   

If an owner has not been identified after the holding period, the animal will be evaluated for adoption. To learn more about procedures for stray animals visit our  Intake Process  page.

The holding period for found dogs in the city​ is 10 days.

The holding period for found dogs in the county is 6 days.

The holding period for found cats is 6 days.

Cats ar e allowed to roam freely in Latah County. If you feel a cat is indeed a stray, please contact us prior to bringing the cat in. If the cat is friendly and you are able to handle it, please put the cat in a carrier and call HSoP to let us know you plan on bringing in a stray cat. We currently cannot accept feral cats.

Stray Pets Found After Hours

If you found a stray dog in moscow city limits, you may call the non-emergency police line at (208) 882-2677 to have a moscow police officer impound the dog at hsop. the dog will be placed in our indoor kennels with food, water, and a bed until hsop staff arrives the following morning. we will scan the pet for any identification, and start the process of reuniting the pet with their owner. , if you found a stray dog in latah county limits, you may call (208)882-2216 to have a latah county deputy impound the dog at hsop. the dog will be placed in our indoor kennels with food, water, and a bed until hsop staff arrives the following morning. we will scan the pet for any identification, and start the process of reuniting the pet with their owner. , there is no assistance for stray cats found in moscow or latah county., if you find an injured stray pet after hsop and the local veterinary clinics have closed, you can call washington state university veterinary teaching hospital at 509-335-0711., owner surrendering companion animals.

We understand there are circumstances where finding your pet a new home may seem like the best option… In the event you can no longer care for your pet, contact us at (208) 883-1166 to discuss how HSoP can help.

While we would love to accept all animals, for the safety of our animals and staff we are unable to accept the following:

Animals with known aggression problems or behavioral disturbances, which would prevent them from being adopted

Animals that have bitten someone

Animals with known contagious or fatal diseases

Feral animals

How do you surrender a pet?

Please understand that as a limited-access, no-kill facility, we do not have room for all animals.  In order to stay a no-kill facility, HSoP does not euthanize to make space. 

That being said, to adhere to our no-kill stance we are unable to offer “walk-in” owner surrenders .  Please contact HSoP to discuss our owner surrender process prior to arriving at HSoP with your owned pet.

How many animals we adopt out decides how many animals we can take in, and this includes stray animals.  Once HSoP reaches our care capacity, we cannot take in more animals.

Call (208) 883-1166 OR email: [email protected]

Owner Surrender Fees:

Feline Owner Surrender Adult

Feline Owner Surrender under 6 months

Canine Owner Surrender under 2 months

Canine Owner Surrender 2-6 months

Canine Owner Surrender Fee Adult

To help HSoP better find the best possible home, we ask owners to fill out a personality profile for their pet.

HSoP also requires a copy of any medical care an owned animal has received.  Including but not limited to, spay/neuter and vaccination information. HSoP asks for a copy of any medical care provided, but surrendered animals are NOT required to be up to date on vaccinations, spayed or neutered prior to arrival.  

Hours of operation

Open Monday -  Saturday from 1:00-6:00pm, dog kennels close at 5:00pm

Closed Sundays

If HSoP does not have space, what next?

View our resource page for Pet Rehoming Services and Assistance .

If your pet is spayed/neutered, we can help advertise your pet on our Petfinder page . We will create a courtesy listing for your pet, and advertise them along with our other adoptable pets. HSoP will only assist in the advertising, and you will be in control of the re-homing process. You will decide if there is a re-homing fee, home checks, or any other adoption requirements for your pet. The goal of courtesy listing is to help your pet find a new home, without needing to come into HSoP. If you would like HSoP to courtesy list your pet, please call us at (208)883-1166.

Alternatively, you can list your pet to be rehomed through Rehome by Adopt-a-Pet. This service allows you to create your own free listing to advertise your pet to others. It offers screening questions, resources for choosing a good family, and full control over where your pet goes. Your pet does not need to be spayed/neutered to use this service, but the new owners are obligated to have your pet fixed within 30 days of adoption. The adoption fee is passed along to the referring shelter or shelter of your choice, which helps us to care for any homeless pets that make their way into our facility. 

If you need assistance getting your pet spayed/neutered, click this button: 

• Does HSoP euthanize animals? The Humane Society of the Palouse is a low/no-kill shelter. HSoP will not euthanize adoptable animals due to space. We’ve stayed true to our mission for 45 years and are committed to preserving and nurturing the lives of all the rescued animals in our care. We reserve humane euthanasia only in instances when animals are suffering greatly with no potential for relief, or if an animal is so aggressive that he or she presents a danger to people or other animals and cannot be safely handled or placed. The decision to euthanize is never made lightly and done only with the best interest of the animal in mind. HSoP is committed to providing all of the animals we rescue with the individualized and compassionate care they need and deserve until they are adopted by responsible, loving people.
• How many canines does HSoP help per year? Each year HSoP provides temporary housing for anywhere from 200-300 dogs.
• How many dogs are returned to their owner, and how many are adopted out per year? For stray dogs that are found within Moscow city limits, HSoP on average will be able to reunite 60% with their owners and 40% will remain in shelter care until adopted. Whereas stray dogs that are found outside of Moscow city limits, HSoP on average will be able to reunite 40% with their owners and 60% will remain in shelter care until adopted. We strongly encourage all pet owners to equip their pets with accurate ID to increase the likelihood of them coming home if they ever get lost. We encourage microchip ID for all pets, and strongly recommend a collar with an ID tag containing the owner's contact number.
• How many felines does HSoP help per year? Each year HSoP provides temporary housing for anywhere from 200-300 cats. HSoP generally has more cats than dogs
• How many cats are returned to their owner, and how many are adopted out per year? For stray cats that are found within Moscow city limits, HSoP on average will be able to reunite 10% with their owners and 90% will remain in shelter care until adopted. Whereas stray cats that are found outside of Moscow city limits, HSoP on average will be able to reunite 1% with their owners and 99% will remain in shelter care until adopted. We strongly encourage all pet owners to equip their pets with accurate ID to increase the likelihood of them coming home if they ever get lost. We encourage microchip ID for all pets, and strongly recommend a collar with an ID tag containing the owner's contact number. Cats should wear breakaway collars if possible.
• How is HSoP funded? For a more detailed view of HSoP finances, visit our Financial Transparency page.
• How much funding needs to be donated or raised by HSoP to make up the 35% and 8% of the annual budget? Each year, HSoP has to raise over $80,000 through donations and fundraising just to keep our doors open. ​ This is why any size donation is greatly appreciated. Without the generous and continued support of our pet community, HSoP would not be able to do what we do. Donate today!
• Is the Humane Society of the Palouse part of the Humane Society of the United States? No. HSoP has no affiliation with HSUS or the ASPCA. Though we do look to the national animal welfare organizations to stay current with best practices, we do not receive funding nor are we affiliated with them. HSoP does apply for grants through these large national organizations, however HSoP does not receive annual funding from the HSUS or ASPCA.
• Who is involved with HSoP? City of Moscow, Chief of Police City of Moscow owns the building and pays for utilities and make up 22% of HSoP yearly budget. Latah county provides 10% of HSoPs’ yearly budget. HSoP presents to the County Commissioners every year to request funding. HSoP Voluntary Board of Directors 14 members who bring a variety of expertise to the organization. HSoP has a full time staff of 5 that include: Shelter Director Animal Care Attendants Public Relations Manager Countless Volunteers
• Does the Humane Society of the Palouse pick up stray animals? The Humane Society does not pick up animals. Stray dogs found within Moscow city limits can be reported to the Animal Control Officer by calling (208)882-2677. If a stray dog is found in Latah County, citizens can call the Latah County Sheriff’s office at (208)882-2216 for assistance, but do so knowing there is no animal control for Latah County. There is no animal control for stray cats.
• Where does HSoP list stray or impounded animals? HSoP lists all stray or unclaimed animals on our Facebook page. To see the most recent stray and impounded animals, please visit our Facebook page through this link: Humane Society of the Palouse | Facebook
• If my pet is missing, could it be at the animal shelter? Hundreds of companion animals come into the shelter every year from Latah County. If your pet is missing, it is important that you contact the shelter as soon as possible so that a missing pet report can be completed and shelter staff can be notified to look for your pet. It is also important that you visit the shelter in-person and look for your pet on a regular basis. Please remember that it is the responsibility of the pet owner to search for their missing pet; however, HSoP will do everything possible to assist you in doing so. We also encourage posting a photo, description and information about where your pet went missing from as well as when to local lost and found groups on Facebook.
• What happens if my pet is brought to the shelter? If your pet is not readily identifiable by tag or microchip, your pet will be held for a stray holding period. Dogs found in the City of Moscow have a 10-day holding period. Dogs found outside of Moscow but within Latah County have a 6-day holding period. Cats found anywhere within Moscow or Latah County have a 6-day holding period. The Shelter will make every effort to contact you regarding your pet during this time. Reclaim fees apply in each situation and must be paid prior to reclaiming your pet. Unclaimed pets become the property of HSoP following the end of a stray holding period. Once this happens, they start the process of becoming ready for adoption. Please ensure that all of your pets have accurate ID to increase the chance of being reunited with them if they ever get lost.
• What does it cost to reclaim my pet from the shelter? Pet owners are charged an impound fee of $20.00. To reclaim a dog that lives within Moscow city limits, if the dog is not already licensed with the city, the purchase of a lifetime license is mandatory. The license is $25.00 for altered dogs and $35.00 for intact dogs. Boarding fees of $10.00 per day are charged for each day of impound after the initial twenty-four hours of arrival at the Shelter
• Do I have to have my pet spayed or neutered? Spaying or neutering is not required for reclaimed pets, although we encourage responsible sterilization of pets and offer assistance through S.N.A.P. Spaying or neutering your pets can prevent unwanted litters and even prevent some cancers in your beloved cat or dog. There are already so many homeless cats and dogs at the shelter, we don't need anymore! If you are in need of assistance having your pet spayed or neutered, please apply for our Spay/Neuter Assistance Program (SNAP).
• If I witness what I believe to be an act of animal cruelty, who do I call? Humane Society of the Palouse encourages the public to IMMEDIATELY report acts of animal cruelty or neglect to Animal Control by calling (208) 882-2677 if occurring within Moscow city limits, and (208) 882-2216 if occurring in Latah County. HSoP does not have the ability to report cruelty or neglect secondhand. If we are contacted about situations of this kind, we will direct them to contact local law enforcement.
• Does HSoP offer veterinary services to the pulbic? Though we would love to offer spaying/neutering and vaccination services to our local pet community, HSoP does not have the ability or facilities to do so at this time. HSoP does offer assistance through our Spay/Neuter Assistance Program (SNAP), and microchipping services. For a list of local veterinary services, please view the Veterinary Services resource page in the HSoP Resource Library.
• Does it cost money to surrender an owned animal? Yes. HSoP does ask for a small donation to help provide care for owned pets that have been surrendered. Please visit our Owner Surrender page to learn more.
• How old do I have to be to visit the shelter? Anyone is welcome to visit the shelter during our open hours! We do have some restrictions about who can see and interact with shelter pets: - You must be at least 18 years old to enter our dog kennels or to interact with our adoptable dogs without a parent or guardian present. - You must be at least 18 years old to interact with our adoptable cats without a parent or guardian present (unless you're working a junior volunteer shift). - Those 17 and under are welcome to visit the shelter and interact will all of our adoptable pets, so long as they're accompanied by a parent or guardian over the age of 18.
• I'm going on vacation, can you board my pet? No. At this time HSoP does not offer boarding services for pets. There are several boarding facilities throughout Latah County and most vet clinics will also board. For a list of local boarding services, please view our Pet Boarding Services resource sheet in the HSoP Resource Library.
• I found a wild animal hurt in my yard, what should I do? HSoP is not equipped care for wildlife. If you've found an injured or orphaned wild bird or animal, please call Palouse Wildlife Rescue and Rehabilitation at (208) 614-2273. For more information, please visit their website: Palouse Wildlife Rescue and Rehabilitation
• I found a feral cat, what do I do? HSoP does not have the ability to provide care for feral cats within our facility. We do have a Trap-Neuter-Return (TNR) program for feral cats living on owned property in Latah County. The program intends to reduce feline infectious diseases and homeless cat births in our region, by providing feral cats with vaccines, spay/neuter surgeries, and ear-tips for identification.
• Why can’t I bring my animal to the Humane Society of the Palouse if I live outside of Latah County? HSoP does not euthanize to make space. We do not have the capacity, space, or manpower to receive animals from outside of the agreed jurisdiction we have with the City of Moscow and Latah County. We recommend contacting the shelter that services your county and they may be able to help.

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intake manifold gasket help

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I'm sure the topic has been beaten to death but i found myself in a tough situation. i recently bought a 97 AWD Safari with 80k. i replaced lots of suspension parts , lift, tires, ect. i had big dreams for this van that are suppose to be reliable and capable of adventures. the van came with a considerable amount of rust as it seems to have sat for a while. noticing some goo in the radiator, i took it to get a proper system flush. Apparently there was oil though out the coolant system and i have leaking intake manifold gaskets which need to be replaced along with raditor hoses ect. a $2,000 job. i am can work on cars so i am considering doing it my self. I keep reading different stories about how involved this job is. what else should i replace while i'm in there? can the job be done from inside the vehicle? i don't have to pull the engine do I ? anything thing important i should need to know, important resources or parts to buy will help. should I replace any sensors. fuel system parts, lines, hose ect? i have to much money to into the van to get rid of it, start over , just to possible see the same problems with another astro or safari. i want to keep this dream alive. thanks Eric  

It's an intake on a v6 so it's not a big deal. BUT it's buried in a van. Consider that. See if there is coolant in your oil. That can be fatal to the engine bearings. in for a penny, in for a pound.  

i did a a chemical block test and seem the be just fine. the radiator shop filled it up with water, and now i'm seeing water in the exhaust. is this also a sign of failed intake gasket? i getting ready to start the job, i appreciate the part recommendations. replaced parts will be; water pump thermostat radiator upper and lower hoses spider injectors intake gaskets bolt set valve cover gasket.. plus whatever i break  

I have a writeup on the plenim area. Should be roughly similar for your van. Lots of writeups on intake R&R, so i just made pics with detailed descriptions on what I thought was missing. Thats 3/4 of the way to the intake gasket, so it could help if you want to do your injectors. I think its possible to remove the intake if you just take the throttle body off and leave the plenum on, but as othwrs have said, might as well do MPFI since CPI is known to go out on these vans. Get lots of sandwich bags to label and hold your bolts, or a partitioned cardboard tray of some sort, and masking tape to label all of the electrical connections. The plenum area has like 14 bolts for all the stuff, and you will probably also need to remove some stuff on tbe front and back to take it clean off.  

Hi,and welcome,I think I missed that before.Was going to ask a bunch of questions,but,do not feel like being up late and babysitting the PC.So,-1- do not assume you need to replace hoses and other stuff for a bit of grunge in the rad. 2-water vapor is a byproduct of combustion, but if it is a lot,yes,bad intake gaskets can allow coolant/water into the combustion chamber/exhaust.You have 2 forces working there,coolant pressure and vacuum.Not going to get into it more other than with what limited info you have provided,I would replace the intake gaskets first,then we can go from there.If you would like more info on all these problems,PM me your phone number,a somewhat OK time to call you, when you have about 15 minutes, and write down your questions beforehand.If you do decide to first replace the intake gaskets(my recommendation,either way), do not make a mistake lots of people have,take a form of flashlight and inspect all the stems and heads on the intake valves,look for carbon buildup.They may need to be cleaned, to prevent upcoming problems.Bob  

That's some great advice from Bob My first time doing this job was on my 98 back in Feb of 2007 it was 26 degrees out, I was working in my driveway and I had to use my motorcycle to run for parts.... lots of profanity seemed to help at the time... On the 98 I was adding coolant frequently and could smell coolant in the exhaust fumes, I also did the spider upgrade at that time I just completed this job on my 04 a few days ago, it went fairly easy this time around I see you're planning on a new radiator that's good with the shroud out of the way you'll have more access to the intake and front of the motor There will be a lot of dirt and crap along the intake to head mating area, be sure to scrape and blow all that out of the way "first thing" so it doesn't fall into the lifter valley You'll be doing 3/4 of the work from inside the van so I removed the passenger seat (four 18mm nuts) it makes it so much easier to work I removed the throttle body, alternator and oil fill tube for more clearance, putting the intake back on is tricky and you'll want all the clearance you can get. Take care with the alternator wires they are known to be brittle, I found that the hard way on my 98 it would not charge after I put everything back together Plus you'll want to loosen the AC compressor mount so you can get at the front left intake bolt....my compressor is seized so I just removed it for replacement that allowed me to get the AC hose completely out of the way mark the plug wires before disconnecting them and pull them off to the side, disconnect the wire harness and pull it out of the way before you remove the distributor be sure to mark the rotor location as well as the "distributor to intake location" and it'll be a simple drop in when reassembling once everything is disconnected and the intake unbolted it'll take some prying to free it from the heads, (mine was stuck real good) then it comes out through the interior while the intake was off I replaced the valve cover gaskets, the added room with the intake off helps my intake had serious pitting at the water jacket ports, I wire wheeled it the best I could then used a hand held blaster with glass bead to clean them down to the aluminum, I gave the intake a good cleaning inside and out then I spread a generous coating of sealant on the water jacket areas just before installing it. also put a good 3/8 thick bead of sealant where the intake mates to the block, no gaskets goes there When installing the intake get someone to help you guide it into place, this is where another set of hands really comes in handy Installing the distributor you have to rotate the rotor about 20-30 degrees counter clockwise while inserting the distributor, so the gears will mesh and at the right spot for the dist and oil pump drive to line up....  

awesome thanks guys. ill keep everyone updated through out the process if i have any questions.  

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