intake gaskets this weekend...anything more I should know?

[GenerationX]

In order to remedy the #2 and #5 spark plug problem (you early OHV owners know) I plan on doing the intake gaskets this free[U/] weekend. I did do a search and couldn't come up with much on the procedure.
I learned that the intake manifold is part of the valve cover flange so I'm replacing v-cover gaskets too. Consulting Haynes it seems like it is pretty straight forward to replace (but doesn't from the book always seem that way?)
So my Q is that when you guys did your gaskets did you run into any snags or anything that the haynes book leaves out?
It's just that I have to drive to my parent's to work on this and I don't have a spare vehicle if anything goes wrong. Thanks in advance.

Garrett

 

[GenerationX]

ttt

I got plenty of RVT and shop rags to cover the holes. I'm ready to go at it. any suggestions?

 

[Luv2explorer]

Take your time!! As you must know, patience is an absolute MUST while working on x's. I ran into a snag on mine where the lower intake bolts were stripped. Evidentally the previous owner had messed with it, and messed it all up. Mark those little hoses too, you dont want to reverse any of them. Follow the manual, and you should be just fine. Good luck- and let us know how it goes!!!

 

[PekingMan]

YES, take your time. I just got finished with mine about 2 weeks ago and if I hadn't had a bolt shear off, it would have taken about 2-3days conservatively. Everything runs great now. You may have a time constraint if you want to have this done in just the weekend. I might also suggest getting the Chiltons book in additionto the Haynes. It has better pictures and inlcudes a few more things in it that you will run into. I have found that each leaves out some stuff but the two combined for reference covers just about all of it.

A couple of things to point out. READ AND DOUBLE CHECK THE TORQUE SETTING ON BOLTS!! I can't emphasize this enough. Make sure the units are right! ie.. ft-lbs, in-lbs, N-m If you don't have a torque wrench, this might be a good time to buy one. You will use it forever and save you from some many future headaches.

Take the hood off. This job is much easier if its off. Just make sure to mark the bolt locations before you take it off so you can align it properly.

The valve cover gaskets may be tricky. This is because they will want to slide around between the valve cover and the cylinder heads. To avoid this, seal the gasket to the valve cover and let it set before you put silicone on the other side for the cylinder head. This will not be a problem with the lower intake manifold gasket because the front left bolt is actually a stud that comes up from the block and will align everything for you.

Be very careful with the fuel injection wiring harness. Breaking something on that will make you have a bad day. 90% of all difficulties I had doing this did not come from the engine itself, but all the wires and accessories to the engine. A second pair of hands will be necessary to hold the wiring harness out of the way when you put in the lower intake manifold gasket and lower intake manifold.

OK, I hope I didn't scare you. It's not that hard. Just be patient and make sure of everything you do.

 

[GenerationX]

Well I didn't do the job yet because I was waiting on a radiator to come in and it didn't yet. So if I get the radiator this week I'll do the job this coming weekend.:frustrate

 

[ajevenson]

Another thing, dont pull a heavy load for a few weeks after you've done the procedure. I put new gaskets on mine and towed a trailer two weeks after. The first 100 miles was ok but then the truck started pinging and running crappy. When I got it home I noticed that it was leaking oil again and that the MPG's were poor.

My advice, do the gaskets, wait a couple of weeks and then retorque the intake before you do any heavy pulling or long drives.

 

[GenerationX]

ok..but I can still drive it right? just don't pull any loads or beat on it? I usually take it easy on my X just because of the parts it needs and I've never pulled a trailer. thanks for the advice.

 

[Luv2explorer]

You can still drive it, just take it easy.

 

[irtySanchez]

Keep us up to date on this one. I have this same job lined up in two weeks. I haven't done this one either, so I too will be heading into uncharted territory.

Good Luck!!

 

[oahrens]

Just a couple of notes----
Label all the hoses and wires, especially around the vacuum tree. I rubber banded paper labels to the hoses and when I went to put them back on..I found something on the hoses(antifreeze?) made the ink smear so be warned.
Also pressure test the cooling system before starting.

 

[GenerationX]

I don't have a pressure tester What would I use instead?

 

[GenerationX]

Well guys it's done...I started at 7:30 Friday night, worked until about 12:30am, sleep and worked on it for 5 more hours had the intake gaskets done by Saturday afternoon until I had to got to a Lansing Lugnuts baseball game. then at 5 on sunday I got back on it, worked for 6.5 more hours putting it all back together, this morning filled it up with coolant, ran it for 20 min. but it's wierd how the coolant level didn't rise and fall in the radiator after those 20 min. The dang thing was getting hot but not too hot according to the guage. The thermostat is newer so I know it should've been working. It's all good now, I drove it to work this morning and it ran good. The coolant's full, I'll check it again in the parking lot after work.

You could tell where the #2 and #5 intake port was leaking; there were traces of sludge/oil going across the seating surfaces. The most time consuming was the cleaning. Mostly due to the gunk build-up in the manifold and intake ports. 103k worth of gunk in the ports was like YUK!!! I blocked off the passageway just above the intake valve with pieces of shop towel so stuff wouldn't fall down there and took my chisel and scraped all the crap off. The manifold side of the intake port was crappy too almost to the point of blocking the injector spray. I didn't have to take off the hood. I'm kind of a little guy so for all the far back work I just climbed up and kneeled on a board that I put across the engine bay.

Anyone doing this job, a shop vac is a must. Even with rags covering up ports, and oil galley, you get dust, and bits all over that fall past and get onto your heads. And after it's back together and you cycle new coolant in, you should change your oil & filter to get any particles.
Man I'm so glad that this is done. With my intake ports nice and clear I bet it's worth a few more horses. I'm also disonnecting my pcv system (not plugging it up) after seeing the horror inside my manifold.

Well if I've helped anyone I'm glad, but if I can be anymore help just send a PM or post it here and I'll try to give you a hand.
Sorry about this long post too but I think this would help out.
Garrett

 

[88vert]

Were all the bolts on the upper intake easy to get at?

 

[GenerationX]

Yup. with all the wires and accessories out of the way they were. They don't hide them under the upper plenum like you think they would. they placed the bolts between the runners of the plenum right under the open space and I could get to them easily.

Garrett

 

[88vert]

Thanks Garrett i will be doing mine soon but the weather has to cool first.Thanks again for posting everything

 

[GenerationX]

oh man...why wait? I'm in michigan and it was still 90+ degrees while doing this job how hot is it where your'e at Brad?

 

[88vert]

Its 94 today and very muggy.It was 131 at work yesterday I work in a heat treating factory

 

[GenerationX]

I used to work in a blow molding plastics place but I don't think I ever saw it get that hot inside

 

[Luv2explorer]

Garrett- Nice job man! Glad to here all went well. Howz she run??

 

[GenerationX]

There's still a miss in the engine, only when idling though. I still have to pull the plugs and clean them as well as fix a loose vaccum line. I also may have messed up the air charge temp sensor when I cleaned the intake so I'll replace that if none of the above helps it. I've been babying it so I don't know if it has more power or not. Other than that it went well, nothing leaking