Conquering Fears Head On, or in This Case Heads Off

2004 Chevy Malibu 3.5 V-6 Engine Block

This week, I started the head gasket replacement on the 2004 Chevrolet Malibu LT with the 3.5 L V-6. I knew I had the skills to complete the job, but I had two fears with this project. My first fear was that the hardware to the exhaust manifold would be seized from rust. The second fear was cracking a head bolt. Both fears were based on damaging engine parts that I could not repair with the engine in the car. There is no room to extract broken bolts, drill larger holes, and tap for a larger fastener. I respected my fears, moved slowly and carefully, and I prevailed.

The exhaust manifold was surprisingly easy to remove from the engine block. I soaked the areas on the top of the exhaust manifold near the head with penetrating oil, but I could not get a good angle to spray the bottom of the manifold. I carefully turned the rachet, and the nuts/studs came free from the top and the bottom. I had difficulty with the other end of the manifold where it meets the catalytic converter. I also soaked these areas with penetrating oil. However, I could not get the hardware to break free with a short rachet handle. I carefully applied more leverage with a bigger rachet and was successful. I took my time, and all connections were free.

The head bolts were easier to remove than I thought they would be. The initial quarter-turn on each both required constant torque, but each one moved. When I work on the car, I replace the bolts once I remove a part. For example, the passenger side head has the alternator bolted to it. Once I remove the alternator bracket, I put the bolt back in the bracket hole in the head so I know where it goes. Because I had these extra appendages attached to the heads, it was easy to pick up the heads. My third fear was the head being stuck to the block.

I have conquered my fears for this project. It’s all cleaning, sealing, and reassembly from here. I still fear doing the job correctly and seeing if the car will start, but I always have these fears on projects like this. What do you do when faced with a fearful part of a project? Share your experience below in the comments.

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