I cut the heads off 4 of the old intake bolts to use as guides for when I reinstall the intake. And I cut slots in the for a screwdriver.





Started with a clean valley.



Then I coated it with axle grease and using the studs as guides I set the intake down and tapped on it with a rubber mallet to help seat it.






Pulled it back off and the intake had good transfer of the grease to it with no high spots that I could see.



I did mange to drag it across the front core support but that is the only area missing grease.




And WHAT a mess... But someone has to clean it up.




OK now all you gearheads I'm open to any and all suggestions before I try installing this intake manifold again. I do think using the old bolts as guides will help a lot.

 

using the old bolts as guides makes it easier... Keeps the gaskets in place, and such.

As for the cleanup, isn't that why we have kids?

 

Or use a good inspection sticker scraper to make short work of the cleanup and some carb cleaner or brake cleaner to get rid of the residue... Those old intake bolts used as guides are a great idea to keep things lined up

 

Is there anything else anyone thinks I should check prior to trying to install the intake again? I'm out of ideas here but really don't like the idea of installing this intake manifold again only to have it leak on me again. But short of baggin this intake and getting another AirGap I don't know what to do.

 

This time, you should be fine installing the intake. Once the head surfaces are cleaned up, use a bead of RTV on both china walls, new intake gaskets and bolts torqued to spec should take care of the issue. Using those vendor supplied gaskets on the china wall was likely the reason the intake wouldn't seal up properly.

 

Only on the first try did I use the rubber gaskets on the second try I used Right Stuff on the china walls. I'm hoping having the guides will get this to go on straight and even. I did find some THICK 0.125" thick gaskets if I have bad luck again.

 

I never used the "Right stuff" but from what it says it's fast set up time.
I use the ultra copper on just about everything and have done so since i had an issue with the LA motors leaking at the front/rear intake. Back then all you could get was cork gaskets and they would leak. I coated them with the ultra copper gasket maker and it fixed the leak. Been using it ever since and it has not let me down. The fast curing time may be too fast by the time you mount it and get it torqued down. Just a thought.

 

Yeah, the fast set stuff might be a contributor... I use RTV, lay down a nice bead, give it a few minutes to 'skin over' good, then set the manifold.

Also, if you have a mechanics straightedge, wouldn't hurt to check the manifold mounting faces......

 

A member on my Jeep forum mentioned that he thought the intake wasn't making contact on the upper area of the intake & heads. So I decided to do some checking with some bluing compound. I spread it onto the manifold around the mating surfaces and on the bottom just to check clearances.



And Dang Nab it wouldn't you know it but it was hitting that valley pan I'd installed from UTAwesome Performace. So I pulled it out and BOOM it fits.



Have good contact all the way around the block.



I used some Edelbrock Performance gaskets this time. Sealed around the water jackets and the china walls.



Used the guide bolts I made and set it done on the block.



Then reinstalled the throttle bodies and fuel rails. I did mange to cut two of the o-rings on two injectors.



Installed a new serpentine belt tensioner & idler pulley.



This belt is supposed to be the proper belt for a 5.9 w/o A/C but it's too short. It's 88.4" long so I think I need a 90" or 91" long belt but need to measure tomorrow. The belt I have barely fits and I'd got a rough measurement of 89" off it. It doesn't have any markings on it so I don't know a brand or part number.

 

I've got to get the radiator installed and everything hooked back up before I can start it and make sure that this was the issue but I have a better feeling about the way the intake went on this time. It seemed to sit in there better. So I've got my fingers crossed that this was the problem.