I am going to install my SR base manifold this week :D and have a couple ?'s so I know what I am getting into.

What will needed to be removed?

What gaskets will be needed besides the intake?

I also read in a Haynes repair manual that you have to chase the threads in the bolt holes using a tap which I dont have is is this needed?

Also can I leave the runners and plenum attached and take them off the base togather?

 

I just went through this a few weeks ago.

You'll remove basically EVERYTHING that is on your engine on top..
I'd say drain your coolant, so it won't make a huge mess for ya 1st.

You'll be taking off your Thermostat housing (to put on the new one), you will also have to transplant a coolant fitting that is in the front of the intake manifold, aswell as a coolant temperature sensor. Then Intake system, Distrbutor, Fuel rail, injectors. Also you might have to remove your windshiled wiper motor-cover to be able to remove your drivers' side valve covers.

I just used the heads-to-intake gaskets I had lying around.. Used PLENTY of Sealant Grey on the front and back of the block. Hopefully it won't leak when I start 'er up..

On my intake the threads were perfect.. I just ran the bolt in there to test before putting it on the engine and didn't have to tap nothing.

And finally you can't remove your plenum and runners in one piece.. Fuel rail is in the way...

Good luck.. Have PLENTY of drinks and music around.. :cheers:

 

I just replaced my intake manifold gaskets and can answer some of your questions.
I removed the Air diverter switch (I think that's what it's called) so I could get to the fuel lines. You have to remove the MAF, Plenum, distributor, runners, EGR tube and thermostat housing. You can leave the fuel rail on, but I had to take mine off because I sent my injectors out for cleaning and testing.

You'll need some RTV silicone to seal the ends of the intake manifold, distributor gasket, EGR tube gaskets, thermostat gasket and probably some new runner gaskets. It's cheaper to buy an intake set which includes all these plus a throttle body to plenum gasket. I bought mine a while ago and can't remember what I paid. Most people recommend the Felpro gaskets, I bought mine before I'd heard this from carparts.com and hope I won't have any problems. Your SR setup may be different.

You have to chase the threads because of all the old sealant that gets clogged in there will throw off your torque readings when you put it back together. Use a 3/8x16 tap as I recall. Also clean off your intake bolts, they actually seemed worse than the threads. Also put sealant such as permatex #2 on the bolts when you put it back together. I bought a metric tap and die set at first because it seems everything on this car is metric, but as you can see I ended up using SAE size to chase the threads. Now I own a metric and SAE tap and die set! (I just love buying tools). To save some money, just buy an individual tap and a handle and you're in business.

Mark everything, and take pictures/video and you'll be good to go.

Hope this helps,
Ron

 

If you don't have one, buy a digital camera and take pics if you don't think you'll remember how things go back together.

We can probably get get you out of a jam, if you get stuck, if you can post pictures here.

Otherwise the other two post have covered most of the important stuff.

 

Thanks guys I hope to get started tomorrow.

 

Where can I get the runner and TB gaskets?

 

Are you using stock runners with an accell (SR) lower base?
You will need the larger gaskets from LPE I think no matter what.. I am not sure how it will fit with your stock runners though..

 

Yes I will be using the stock runners. I looked at LPE I think the High flow runner gaskets should work. They only offered 58 TB gasket and I am going to keep the stock.