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Replaced Intake Manifold Gasket, more problems now than when I started

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Old Dec 11, 2025 | 06:45 PM
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Default Replaced Intake Manifold Gasket, more problems now than when I started

1995 Dakota 5.2l v8 automatic
I'm learning everything myself, and maybe I'm really bad at that. But I bought a truck in need of a new IMG. Thought I could do it. Took photos meticulously over a period of several days as I found time to tear it down and install the gasket. Got everything back together, had a few extra hoses I wasn't sure where went. Followed the vacuum diagram, took a look at the lines on my '92 v6 4x4 (not running now, needs a transmission). And by the end of it, I got two loud pops while cranking. Fuel was resynched properly. Now oil had a slight gas smell, changed the oil and it still won't start. Not sure if I should even continue working on vehicles, or if I just need to buy a horse at this point. So fed up at this point.
 
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Old Dec 11, 2025 | 07:40 PM
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Did you have the distributor out??
 
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Old Dec 11, 2025 | 07:43 PM
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Yes, it was a part of my Haynes Manual procedure and I did it without much thought even though, in hindsight, I don't think I needed to pull it. I was careful to mark everything, but perhaps I bumped the Rotor somewhat. Anyway, I put No. 1 Cylinder back at TDC and verified the Rotor was pointed to No. 1 Plug Terminal.

Going to get back out there and unfoul the plugs, disconnect Fuel Pump and Ignition Coil and blow out any gasoline. put everything back in and hope to get spark.
 
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Old Dec 11, 2025 | 08:19 PM
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Put number 1 at TDC in firing position again, (both valves closed) yank the distributor cap, and make sure the rotor is pointed toward the notch in the distributor body. That should get injector timing close enough to run the engine.
 
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Old Dec 11, 2025 | 08:46 PM
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I did that the first time. I'll let You know how it goes this time.
 
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Old Dec 12, 2025 | 02:00 PM
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Originally Posted by HeyYou
Put number 1 at TDC in firing position again, (both valves closed) yank the distributor cap, and make sure the rotor is pointed toward the notch in the distributor body. That should get injector timing close enough to run the engine.
Had everything synced. Spark plugs were pretty well fouled. Changed them w/ a couple new ones and the six from my '92 v6. Had a weak crank, jumped the battery and again had gasoline vapor coming from PCV Breather Valve Hose into the Air Cleaner Assembly. Pulled the dipstick, it's mixed w/ gasoline. Don't even know where I went wrong. Might have put some vac hoses on wrong but wouldn't think it'd cause me to have gasoline in the intake.
 

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Old Dec 12, 2025 | 03:04 PM
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Might it be the Vapor Canister Purge Solenoid? I might have connected it to the wrong port on the Manifold, but that shouldn't cause this condition should it?
 

Last edited by Arkansas_Dan; Dec 12, 2025 at 03:22 PM.
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Old Dec 12, 2025 | 03:55 PM
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Evap system should only be pulling vapors...... Check the lines, see if there is liquid gas in them.....

Is the two-wire temp sensor hooked up? Should be up by the thermostat housing. If that one isn't plugged in, PCM thinks the engine is -40 degrees, and positively DUMPS gas, trying to get a burnable mixture...
 
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Old Dec 12, 2025 | 05:10 PM
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Originally Posted by HeyYou
Evap system should only be pulling vapors...... Check the lines, see if there is liquid gas in them.....

Is the two-wire temp sensor hooked up? Should be up by the thermostat housing. If that one isn't plugged in, PCM thinks the engine is -40 degrees, and positively DUMPS gas, trying to get a burnable mixture...
It's hooked up. I'm positive everything electrical is connected properly. The hoses ain't right though. Some fell off before I could get pictures. Of course the ends of many of them had become dry, so the ID was larger and it became a guessing game. So I trimmed the dry ends off, tried following the diagram under the hood and peeked at my '92 for reference. Problem is this thing was looking funny when I bought it and I'm not sure it was right to begin with. The Line that goes from the Fuel Tank, for example, what does that go to? Because the label says it connects to the EVAP canister, but I had it photographed going straight to the Intake on the driver side. Tried both ways. There's a couple other lines me problems too.
 
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Old Dec 12, 2025 | 08:46 PM
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You don't want the tank plumbed to manifold vacuum. That's a bad idea.

I would verify the temp sensor is hooked up properly. Keep in mind, there are TWO on your truck, a one-wire sensor for the dash gauge, and the two-wire sensor for the PCM.
 
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