Developed a leak. Engine is a V-6 vortec 4.3. The return hose from the heater core, where it goes into the manifold. I pulled the hose off and backed out the nipple that the hose connects to. The plug on the manifold is split. Cannot see if it is all one piece or can be replaced. Is there a way for this to be repaired or does the whole manifold have to be replaced? Tks cl

 

Can you post a picture or two of the broken piece?

 

I cleaned the plug with acetone, and filled the crack with jb weld, Coated the threads inside and out, then snugged the nipple in place.Don't know if it will hold or not without leaking.
I pulled a photo off the net, looks like it is all one piece. Here is a photo of what i am referring to....Tks cl

 

The nipple threads into the intake manifold. If the nipple is cracked, you can replace it. If the manifold is cracked, you'll need to replace it if it still leaks after your repair.

 

Let it set for 2 days and its still leaking so looks like a replace job. Looked at a couple manuals but can't find much on the removal. Anybody know where i can download a removal guide. Also recommend a good place to order at a good price.

 

There's a good guide in the "How-to" section for replacing the lower intake manifold gaskets, here on the forum. Make sure you use Felpro gasket MS98002T and follow the instructions that come with it. As for the manifold itself, it's a pretty common problem for the coolant ports to pit from corrosion so you might check a local boneyard first.

 

Searching the how to now. Looks like the problem is going to be finding the manifold. Actual Chevy dealer wants around 9 hundred bucks. Napa and Advanced don't carry and say they can't get them. The ones i see online have a caption on them that they are not legal. Something about the ERG.

Nothing local. About my luck.

 

Call around, some boneyard will have a junk 4.3L that they'll sell you the manifold from. Ha, you can probably get the entire engine for a couple hundred!

 

Finally got all the parts and started tearing it down. Ran into a problem The ac bracket has to be pulled out a couple inches to make room to remove the manifold. Got the 3 bolts off, and also found one on the bottom and removed. Still cannot remove. Does anybody have a diagram of what else could be holding this. I have been over and over and cannot se anything thats holding it on. Tks cl

 

Unbolt the AC compressor from the bracket, (do not discharge refrigerant) and move the compressor out of the way. Remove 3 bolts and one nut/stud from the AC bracket. Remove one nut (from the front) holding the PS pump to its bracket. There is one nut holding the power steering bracket on a stud next to the front of the exhaust manifold, it only needs to be loosened, not removed. No need to remove the PS pulley. Pull the PS pump and bracket forward slightly to allow removal of the AC bracket.