Is your car leaking coolant? If so, it may be time to replace your intake manifold. The good news: you may be able to score an intake manifold for less than $100, and if you can do the labor yourself, you’ll save literally hundreds of dollars in labor costs at the mechanic. Here, YouTube car expert ChrisFix walks us through how to replace the intake manifold and gaskets, step by step.
How do you install a performance intake manifold and replace gaskets in your car?
ChrisFix will show you how to remove the throttle body, alternator, fuel rails, and heater hose to allow you to easily install your new performance manifold and replace your car’s gaskets.
Installing a Performance Intake Manifold and Replacing Your Car’s Gaskets
Before you get started with installing your performance intake manifold, you’ll want to be sure you have a clean workspace. Pop your hood and use a leaf blower or compressed air to clear out dust and debris, providing you with a clean space to install your new manifold.
First, remove the negative battery cable and drain all of the coolant. After you disconnect the negative battery cable, go underneath your car and locate the valve to drain coolant. Place a drain pan under the coolant valve
Put coolant in a container you can seal (this is important, as dogs, cats, and other animals often like the taste of coolant, but it can be fatal if ingested). You can take the coolant to an auto shop or other place where it can be recycled.
Second, remove the throttle body by simply unbolting it and moving it to the side. Pro tip: snap a few pictures of your engine before you begin removing components so you have a reference point when it’s time to reassemble. To remove the throttle body, you’ll need to disconnect the idler air control valve, the vacuum lines, the throttle position sensor, and the EGR (you may need to use a wrench to remove the EGR).
Next, remove the bolts that hold the throttle body in place and set it to the side.
Remove the water pump to provide you with access to the alternator. Remove the bolts holding the poly in place, use a breaker bar to remove the belt tension, remove the belt, and pull the spark plug wires out of the way. Disconnect the power cable coming from the alternator, then remove the bracket holding the alternator in place. Loosen the alternator bolts, and remove the alternator.
Disconnect and remove fuel rails next. You may also need to disconnect a wiring harness to completely clear the area and move the fuel rails out of the way.
Now, remove the heater hose from the intake. Simply slide the clip up the hose, then pull the hose off of the intake. You’ll also need to remove the thermostat housing by unscrewing the two bolts holding it in place.
Pull the spark plug wires out of the intake (you may want to label them first). Remove all bolts holding the intake in place. Pull the intake out.
Now, plug the intake ports (foil works well), remove the old gaskets, and spray down the remaining surface with car cleaner, then wipe it down with the abrasive side of a sponge. You’ll see a heater hose running down the middle that you’ll need to remove as well. You may need to replace the fitting of the heater hose to match your new intake. Replace the o-rings if you’re keeping your fittings.
Before you begin installing your performance manifold, check to see if you need to do any retrofitting to meet the needs of your vehicle.
Transfer your coolant temperature sensors from your old intake to your new one, sealing the threads with PTFE tape. Tighten the sensors. Transfer the thermostat and gasket to the new intake.
Install a new heater hose (add a little silicone to the o-rings first). Bolt the hose into place, attach the heater hose, and tighten the hose clamp.
Remove the tinfoil from the intake holes, and set the new gaskets into place. If your new gaskets have pegs that don’t align, simply clip them off. You may need to use some RTV gasket maker (be sure that it’s compatible with coolant) to ensure a tight fit if you have any portions that don’t quite line up). You may want to use studs to hold the gaskets in place while you install your new intake.
Place your new intake over your gaskets, and remove any studs that you used to hold the gaskets in place.
Hand tighten your intake bolts. If you needed to use RTV, allow it to cool for an hour before you tighten your intake bolts. Start with the bolts in the middle, and move outward in a criss-cross pattern.
Replace the harness and fuel rails, then reinstall the spark plug wires in the correct holes. Replace the heater hose and tighten the clamp. Mount the alternator and alternator bracket. Loosen the belt tensioner and replace the belt.
Replace the throttle body, reconnect vacuum lines, and tighten the EGR tube. Finally, fill the cooling system (ensure that the radiator valve is closed). Leave the funnel in place so that air can work it’s way out of the system.
Allow the engine to run while the car gets up to operating temperature, be sure that you don’t see any leaks. Remove the coolant funnel and replace the coolant cap.
Doing Tough Work on Your Car?
If you’re doing intricate work under the hood of your car, there’s no doubt that you’ll have some questions along the way. Let the experts and experienced drivers at Vehicle History give you the answers you need when you hit a point where you need some guidance.
