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guide too re-installing the intake manifold
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PostPosted: Sun Oct 12, 2008 8:42 am 
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Joined: Sun Sep 14, 2008 1:40 pm
Posts: 5164
Location: florida
read these threads first

viewtopic.php?f=44&t=700

viewtopic.php?f=50&t=1877&p=4937&hilit=propane#p4937

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these gaskets work ok,

http://www.mr-gasket.com/ProductsListBy ... election=6

http://www.summitracing.com/parts/FPP-1205/

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http://www.nationaltbucketalliance.com/ ... torque.asp
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read this thread and sub linked info
viewtopic.php?f=50&t=609

watch the video

http://www.youtube.com/watch?v=YdIGZ-tV ... re=related

step 1
pull and carefully clean and degrease the intake mount surfaces...BUTONLY after you bring the engine to TDC on the damper tab and balancer marks and verifying the distributor rotor is pointing at cylinder #1, so you know where its suppose to point during the re-installation then
throw the intake manifold kits rubber front and rear intake seal bars in the new intake set in the dumpster




step 2
clean the block rails and the matching intake surfaces with acetone,or toluene soaked shop rag. clean all previous gasket material and sealant off the heads and block surfaces with a gasket scrapper or razor, and acetone soaked rag, (optional but recommended) then use a steel center punch to dimple the china walls upper surface lightly , and matching lower intake rail area, to provide a firm grip and adhesion for the high temp silicone gasket cement, be sure the corners get just a bit extra silicone during the application of the silicone gasket cement

step 3
place a 1/4" wide bead of black silicone sealant along the length of the center of BOTH the front and rear block rails and both the matched lower intake mating surfaces, just AFTER first spreading a bonding coat on both dimpled surfaces with your finger,and allowing it to bond and dry for 2 minutes so the silicone beads that will shortly be added, and melded/compressed above and compressed between the matched dimpled mating surfaces,you just covered with a thin layer of smeared gasket cement and that bead of sealant on those twin mating surfaces of the block rail and intake will bond firmly place the intake port gaskets and align the bolt holes with the holes in the cylinder heads and put a small very thin bead of silicone sealant around 360 degrees of the water transfer ports,on both sides of the gasket, on both gaskets then place the intake straight down into place so the wet sealant beads mesh, blend and squeeze out a bit.
step 4
drop the intake into place with minimal forward or backward or side to side movement, use a long Phillips screw driver in a bolt hole will help to easily align the intake, tighten slowly in stages working from the center bolts outward, use a #2 Phillips screw driver to make minor adjustments to the intake thru the bolt holes if it moved a bit during the install, then drop the bolts into place and thread all bolts finger tight before tightening any of them,.then torque them down in stages, working in a circular pattern out to the ends.

http://www.nationaltbucketalliance.com/ ... torque.asp

step 5

allow to dry for a couple hours minimum over night,will be better, before use

OPTIONAL but RECOMMENDED

the use a sharp object like a steel punch or awl and plastic hammer to DIMPLE both upper and lower surfaces to give the silicone sealant a firmer grip, by lightly dimpling the surfaces over a large surface realy does increase the bond and tends to avoid leaks

http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=39940

http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=621

btw the correct length , threaded carb STUDS to mount the carb to the intake are far less likely to strip threads in the manifold

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look if your only installing a distributor after a manifold swap,and start from scratch on the ignition timing,
ITS not complicated, pull the #1 plug and put you thumb over the hole tightly, turn the engine in the normal direction of rotation, with a breaker bar and socket until you get compression in the #1 cylinder, as the damper TDC line approaches the TDC timing tab, drop the distributor in with the rotor facing the #1 cylinder,compensate for the way the distributor gear causes the rotor to rotate as in seats,so its seated pointing where you intended, if it won,t fully seat turn the oil pump drive with a very large flat blade screw driver until it will,with the distributor removed and try again, once it seats,facing the correct direction, install and tighten the distributor clamp so its difficult to spin the distributor easily by hand but still possible to spin the distributor by hand, re-install the #1 plug and wire, install the cap and all ignition related wires, use your timing light and set the ignition timing,per the shop manuals instructions, tighten the distributor hold clamp so it can,t move, IF it takes more than 10 minutes your in need of more practice or nearly hopeless as a mechanic.The CLOYES true roller style is vastly superior to the factory link belt design

lets drop to basics,
the crank socket has an index groove that matches a key in the crank snout, and you must use the matched set of timing gears (cam and crank) not for example use the new cam gear with the old crank gear for two main reasons, first the old gears have formed a wear pattern, that won,t exactly match the new chain and that tends to accelerate wear on the new chain slightly, and second , different manufacturers tend to mark and index the gears slightly differently, and while in theory both the pin in the cam gear and the woodrif key in the crank gear limit the chances of a mis-match theres occasionally a couple of degrees of difference in mis-matched sets
be aware that some crank gears have more than one index slot to index to the crank key and each slot is marked and you must use the correct matching marks indicating (ZERO) that match the crank slot marks

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look closely SLOT A uses a different TDC mark (A) than slot (R), which has its own TDC mark(R)
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viewtopic.php?f=59&t=901&p=1462&hilit=puller#p1462
most guys oil the crank snout and heat the crank gear slightly and tap it on with a large socket

but yes theres a tool
http://www.summitracing.com/parts/CCA-4789/
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notice the (O) thats supposed to be indexed at 12 o,clock
and matched to a cam timing gear at 6 o,clock, which temporarily places the #6 cylinder at TDC, you then simply rotate the crank one complete turn, bring the cam timing gear to its 12 0,clock position,and the #1 cylinders at TDC and you can drop the intake on, and distributor in and adjust the valve lash clearance (solid lifters) or pre-load (hydraulic lifters, and set the ignition timing at about 8 degrees btdc as a starting location

you can use a dead blow hammer or the damper tool to install the gear
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http://www.harborfreight.com/cpi/ctaf/d ... mber=41800

http://www.summitracing.com/parts/OTC-6505/

viewtopic.php?f=52&t=90

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read
http://www.centuryperformance.com/tunin ... g-148.html


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http://boxwrench.net/specs/chevy_sb.htm
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drop the distributor in with the rotor pointing at the #1 cylinder, and YEAH! it physically possible to get the distributors rotor to point at any place you want it too by changing the oil pump drive shaft alignment with a large flat blade screw driver while the distributors out of the engine and that's easily changed, but to do it correctly,you want the rotor to point at the #1 cylinder on the compression stroke, so pull the #1 plug, get a large ratchet/socket on the damper and put your finger over the open plug hole and slowly rotate the engine by hand in its normal rotational direction until you see pressure build under your finger as the rotor approaches #1 cylinder location on the distributor base which you should have marked as its supposed to be in direct alignment between the distributor and the number 1 cylinder on the engine,
remember the distributor and cam gears are helical and the rotor turns as it seats so compensate slightly. and the rotor should be just coming into alignment as pressure builds under your finger, once that's done re-install the distributor cap and plug and use a timing light to set the timing, you normally want about 6-12 degrees BTDC at idle and watch it advance to about 37 degrees as the rpms build to about 3000 rpm ok, then have you checked the distributor to oil pump drive shaft length?,
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IF YOUR DISTRIBUTOR LEAKS OIL AROUND THE BASE GASKET..
it seems the distributor is not seating fully against the intake ring gasket and the distributor to oil pump drive is suspected of being a bit to long, there should be about .050 slack MINIMUM between the oil pump drive shaft and the distributor gear.


viewtopic.php?f=52&t=196

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" IF YOU CAN,T SMOKE THE TIRES AT WILL,FROM A 60 MPH ROLLING START YOUR ENGINE NEEDS MORE WORK!!"!


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Re: guide too re-installing the intake manifold
PostPosted: Sat Feb 07, 2009 6:09 pm 
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Joined: Sun Sep 14, 2008 1:40 pm
Posts: 5164
Location: florida
OK, youve installed the intake you got a such a (GREAT DEAL) on used from some guy you don,t know and it seems the intake leaks, now what?
obviously you need to find the reason, if the heads or intake were angle milled, to gain compression, the angles might not match correctly, and might require some re-machining , or a thicker gasket or the intake end rails milled, or the angle of the bolt holes or mating surfaces might need to be fixed to correct the fit,

viewtopic.php?f=44&t=822

http://www.circletrack.com/enginetech/c ... index.html

http://circletrack.automotive.com/79173 ... index.html

http://www.bhjproducts.com/bhj_download ... og_p21.pdf

http://www.goodson.com/technical_suppor ... illing.php



you need an angle gauge, and large caliper to meassure both the intake and the head surfaces, and distances accurately, if they are machined wrong your screwed

http://www.harborfreight.com/cpi/ctaf/d ... mber=95998

http://www.harborfreight.com/cpi/ctaf/d ... mber=47261

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_________________
" IF YOU CAN,T SMOKE THE TIRES AT WILL,FROM A 60 MPH ROLLING START YOUR ENGINE NEEDS MORE WORK!!"!


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Re: guide too re-installing the intake manifold
PostPosted: Mon Feb 01, 2010 3:26 pm 
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Joined: Sun Sep 14, 2008 1:40 pm
Posts: 5164
Location: florida
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ITS not complicated, pull the #1 plug and put you thumb over the hole tightly, turn the engine in the normal direction of rotation, with a breaker bar and socket until you get compression in the #1 cylinder, as the damper TDC line approaches the TDC timing tab, drop the distributor in with the rotor facing the #1 cylinder,compensate for the way the distributor gear causes the rotor to rotate as in seats,so its seated pointing where you intended, if it won,t fully seat turn the oil pump drive with a very large flat blade screw driver until it will,with the distributor removed and try again, once it seats,facing the correct direction, install and tighten the distributor clamp so its difficult to spin the distributor easily by hand but still possible to spin the distributor by hand, re-install the #1 plug and wire, install the cap and all ignition related wires, use your timing light and set the ignition timing,per the shop manuals instructions, tighten the distributor hold clamp so it can,t move, IF it takes more than 10 minutes your in need of more practice or nearly hopeless as a mechanic.
Make sure TDC on the damper is marked with white paint or chalk.
Crank the engine over with a breaker bar on the crank/damper bolt until you begin to come up on compression in number 1 cylinder. (A compression gauge will help if you are not sure how to do this.) As the compression rises up on the gauge, TDC will come around and will land under the pointer. ( I set mine up at 8 to 12 degrees BTC). This is the number 1 firing position.use a timing light and the timing tab to locate the timing on the dampers timing tape after you get it close to correct


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how come its 180 degs out of phase?
I get this question all the time, well here’s something I see lots of guys don’t understand, ONCE YOU'VE INSTALLED A CAM WITH THE TIMING MARKS YOU MUST ROTATE THE CRANK 360 DEGREES BEFORE DROPPING IN THE DISTRIBUTOR, while its true that if the, timing marks are positioned so the crank is at 12 o,clock and the cam gear is at 6 o,clock that the cam lobes will be in the position that fires #6 cylinder that HAS NO EFFECT AT ALL (on finding TDC,) for aligning the degree wheel with TDC,or THE timing tab pointer, for degreeing in the cam, the piston passes thru TDC TWICE in every firing cycle once on the firing/power stroke and once on the exhaust stroke, the cam rotates at exactly 1/2 the speed of the crank so to make it easy to line up the marks they install it with the marks at the closest point 6/12 for easy indexing, rotate the engine 360 degrees to the #1 TDC power stroke and the crank gear will still be at 12 o'clock 12/12 but the cam will be at 12 o,clock also, rotate another 360 degrees and your back where you started. its simply easier to index the cam at the point where the index marks align closely. look at how the cam lobes themselves open the valves when the cam is just installed the #1 cylinder valves are slightly open and the #6 are closed per "Lunati" ‘’YES YOU ARE RIGHT - WHEN CRANK IS AT TWELVE AND CAM IS AT SIX THEN #6 CYL IS FIRING AFTER YOU LINE UP YOUR MARKS AND INSTALL GEAR THEN ROTATE YOUR CRANK ONE REVOLUTION AND THEN DROP THE DIST. IN - AT THAT POINT
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http://boxwrench.net/specs/chevy_sb.htm
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" IF YOU CAN,T SMOKE THE TIRES AT WILL,FROM A 60 MPH ROLLING START YOUR ENGINE NEEDS MORE WORK!!"!


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