Make sure you have a good torque wrench. The intake bolts only take 12 foot/lbs of torque and should be tightened according to the sequence in the service manual. You should certainly replace the water pump bypass hose and the clamps, as its a common leak spot.

 

that's the hose that comes with the plenum kit I believe, I found the TSB on this repair, does it have the proper sequence and torque specs?


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Yes that's the hose that is included in the Hughes kit.

The tsb does include all the correct torque specs and sequences for both the plenum pan and the intake.

 

Well I guess as soon as it all arives I'll do my best to make it happen then..

 

Does the hughes kit also come with the blue loktite? If not, pick up some of that as well.

 

I don't think it comes with locktite, but I've got a few bottles of the red stuff lying around.
what's the difference between the 2?

 

How hard it holds on.

The LAST thing you want to happen, is one of the bolts backing out, and dropping into the motor..... That would make rude, expensive noise almost immediately.

 

Is one of your fuel injectors leaking? If not then I would leave the fuel rail in place when you pull the intake. Sometimes new o rings will roll when you install them and you'll have to fiddle with them a bit to get them to seal.

Why 180º and not 195º (stock)? A lot of guys run a 180º to combat spark knock but you shouldn't have that issue with the new plenum gasket.

If you can fit then I would suggest taking the fan and fan shroud off so you can stand on the ground in the engine to work on it, it'll save your back. If you go that route then make sure you don't scrub the fins on the radiator with your butt and flatten them.

Masking tape and a sharpie is handy when unplugging a bunch of wires, you might want to do that so you don't get mixed up when plugging everything back in.

 

The 180° I have in it now seems to b be working good, so I went with it again.
I don't think any of my injectorsare leaking but I figured since I was removing the fuel rails it'd be a good piece of maintanence.
good call on the tape and sharpie, I got a roll of painters tape to do it.

 

A handy little tip I learned when installing my intake the first time;
Since you should be using new bolts anyway, cut the head off of 4 of the old manifold bolts then cut a good notch into the top of them. This let's you slide the intake over the modified bolts to keep it from shifting around during install, then use a screwdriver if needed to remove them. Make sure to start a few of the new bolts before removing the modified set to keep everything in place.