Hey guys - I've got to replace the intake gaskets on my 91Z (5.7) and before I dig into it, I was wondering if I'll run into any parts that are considered "one time use" (little plastic clips on the injectors?).

I know to get a gasket kit, new oil & filter, & antifreeze - cap and rotor are new, but if you can think of anything that you had problems with or had to replace when doing this, it would be greatly appreciated. I netted a couple how-to's w/search, but nothing specifically mentioned this...

 

O-rings.

If it's the first time you've had teh injection off, i can guarantee that the o-rings from fuel lines to fuel rail are going to be shot when you take it off.

Also, very goood odds that the majority, if not all the injector o-rings will get mangled pulling them from the insnatch and rail.

The dealer can hook you up with the injector o-ring kit as well as the inlet/outlet pieces for about $20. See: https://www.thirdgen.org/techbb2/sho...ail+blue+oring for some part numbers to bring with you.


Other than that, no funny clips on the injectors or anything like that. If you can spare the coin, a few more good things to have would be:
- 8mm x 1.25 tap. Run it through all the runner bolt holes while you have it apart. Makes it go together a lot easier

- new bolts - a nice set of cap head allen bolts makes working with TPI a lot easier than messing with torx
- round head allen key socket - goes along with new bolts. A round head allen key makes working on TPI as close to gravy as it gets.


Another tip: Leave the EGR solenoid bracket 'floating' when you put the intake back on, just don't bolt it down with the intake bolt. This way it's not in your way when you go to set timing. It stays in place just fine between the wiring connnector and vacuum harness going into it.

 

Good time to replace the thermostat if needed.

 

If you buy the complete felpro manifold kit, it comes with 8 of the injector O-rings. So as long as you dont take the actuall injectors out of the rail, you shouldn't need to buy them. Just be careful not to rock them around to much

 

I've never used the fel-pro complete set, just the runners. Good to know though.

BTW, i imagine it does not come with the inlet / outlet o-rings since you didn't mention them? If so, he'll still need to hit the dealer for those, but they're dirt cheap anyway. It's the blue injector oring set that costs like $20.

 

If you are just going to replace the intake gaskets, why are you going to pull the injectors? If they aren't leaking, don't mess with them. Besides, the fuel rails make nice handles for removing and reinstalling the intake.

 

Yeah, unfortunately felpro didn't think through the kit completely, it doesn't come with the fuel line O-rings.

I've always found it easier to pull the fuel rails off to get to the torx bolts on the manifold. When I pull it all off again for siamesing/port/polish, I'm thinking about getting regular bolts with the 6 point head to make it alittle quicker.

Matt