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How to Install an Air Intake Manifold Gasket

If your engine has been overheating, leaking coolant, or losing power, it may be time to replace your intake manifold gasket. This crucial gasket prevents overheating and helps keep your engine running its best. Fix your intake manifold gasket by following the steps below.

Tools needed:

Step 1: Drain the coolant

‌If your car is an automatic, put it in park. If it’s a manual, put it in first gear. Next, set the parking brake and place wheel chocks under the rear wheels. Jack up the front of the car and place it on the jack stand. Make sure you’re using a high quality jack stand to ensure that the car won’t fall while you’re working underneath it. 

Next, drain your engine coolant. For most cars, the plug is located on the underside of the radiator reservoir. Check your manual to make sure, as some car engines don’t have coolant passages in the intake.

  • If your car is older, there may be a drain cock or plug in the radiator engine.
  • ‌For newer models, your car most likely has an engine drain and does not have a drain plug.

‌Look through your manual and locate your drains. Then remove the radiator coolant reservoir cap. If your car doesn’t have an engine drain, you may need to loosen a hose located at a low spot within your engine. Next, you’ll need to drain the coolant. 

If you have pets, keep them out of the garage while completing this task. Antifreeze is deadly to pets, and you don’t want them ingesting it. 

Step 2. Remove the intake manifold

Once the coolant has been drained, you can begin removing the intake manifold. 

Make note of all hoses and wires holding the intake manifold. Take notes, photos, or both for reference. This is key to putting the engine back together once you’ve replaced your gasket.

  • Removing all of the hoses and wires may not be necessary. Remove them one at a time.
  • Picture the manifold unbolted from the engine and facing upward in a manner that allows you to reach the gaskets. It may be possible to leave hoses and wires attached if you don’t have to pull too hard on them.

Next, remove all fasteners attaching the intake to the engine. Using a baggie or a bowl for small parts like fasteners makes them easier to find when it’s time to reassemble the intake, and it also keeps them from rolling under the car.

  • ‌For V type engines, the fasteners will likely be located on top.

‌Consult your manual for the recommended bolt loosening sequence. Loosening and disconnecting them in order will decrease the likelihood of dislodging the part and having it fall out of the engine. If your car is an inline 4 or 6, the manifold may be hanging off the side of the engine. 

In this case, you may need to access some of the bolts underneath the car. Capri tools carries a variety of ratchets with flexible heads for these tight squeezes. Use them to loosen these fasteners. If there is a bracket supporting the intake, remove it before continuing.

If your gaskets are sticky, you may need to lightly pry the intake off of the cylinder head.

  • ‌Make sure all of your fasteners are removed. Be careful with any foreign objects or debris that might fall into the intake ports. When removing nuts and washers, be sure to set them aside so they can’t fall into the engine.

‌Next, clean all surfaces to achieve a good seal with the replacement gasket. Pieces of your old gasket might tear and remain attached to the manifold. If this happens, carefully scrape it off. Use an air blower to remove any excess dirt from the intake area.

‌Step 3. Reinstall the intake

Materials needed:

Consult your manual to see if you need to apply sealant. If your gasket has rubber O rings, sealant may not be necessary. If you need to use sealant, make sure it’s oxygen sensor-safe. A silicone-based sealer might emit fumes that can damage your oxygen sensor.

‌Some engines include dowel pins that you can hang the gasket on. If there are no pins, apply a few small drops of sealer, sticking the gasket to the engine. You don’t want the gasket to move while attaching it.

‌Use a torque wrench to tighten the bolts using your manufacturer’s specifications. You may need to perform the torquing sequence more than once to make sure that the bolts are properly seated.

‌Step 4. Reassemble your motor

In some engines, you may have had to remove your distributor. If you need to do this, be sure to plug it in and align the rotor to your marking. Consult your photos or notes and begin reattaching wires, hoses, and everything that was removed from your manifold.

Use your ratchet to tighten any coolant connections and install the drain plugs. Before tightening fasteners all the way, make sure that all wires and hoses are connected correctly. If there are any left over, consult your photos and your car’s manual to determine where they go.‌‌

Step 5. Start your engine

Turn your heater to its highest setting and start up your car. Warm the car up to running temperature. As your car warms up, the fluid level in the radiator or coolant reservoir will drop suddenly as the thermostat opens. Keep topping off the reservoir as the level decreases. This is called “burping” the coolant system.

‌You can now top off your cooling system with fresh antifreeze and put the cap on securely. Open up the coolant bleeder if your engine has one. If not, remove a heater hose located high on the engine and pour the coolant through the reservoir. If your system is full, then heat will come out of the heating vents.  

Step 6. Finishing the job

Once your intake manifold is full and running smoothly, lower the car and take it off of the jacks. Ensure that it is running correctly by taking a test drive and monitoring the temperature. 

Replacing the intake manifold gasket incorrectly can damage other parts of the engine. Using the professional quality tools offered by Capri tools can make the job much easier. Our tools are designed to be used in small spaces (like engines) and come with safety features that keep you from over tightening fasteners. Check out our full line of products for car maintenance and repairs.

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