Any tips on installing intake gaskets to make sure they don't leak. I've only done them a couple of times without much success. Dealer wants $185 to do them.

Thanks.

 

The best way that I know of is to install the intake and snug the screws. Be sure to lubricate the seals on all sides with Hylomar or a silicone lubricant like Dow Corning 112 or equivalent. Don't use grease. Even vaseline will work. You just need something to help the rubber flow around the intake and the flanges otherwise they tend to distort.

If your engine is stock then your intake is good. If it's been shaved or has thinner head gaskets then you might need to modify the manifold.

I'll assume you're stock. Once you have the manifold in place and snugged up insert your carburetor and mount the air cleaner. If fuel injected then mount the air cleaner to the throttle body and the heads and tighten.

This should hold the manifold in the correct position. Now tighten the manifold screws a little at a time keeping an eye on the gap between the edge of the machined surface of the manifold the the edge of the flanges. This should be kept equal as much as possible. You may need to use a screw driver to pry it one way or another to center it. Once the screws have pulled up tight and your gaps are equal you should be good.

I just reread you post and saw you're not stock. If the heads have been shaved or you're using thinner head gaskets you may have to shave some length off your manifold/throttle body. If you hold just the throttle body up to the heads do you see a little of the port showing? If not you need to shave the TB. I like to see a little cresent moon showing. In other words you should see some of the port, which will look like a cresent moon. When backed off to it's running location it will cause a small gap between the TB and the heads. You need this small gap. The seals need to wrap around the intake a little to help seal. Be sure to do this slowly taking a little at a time and champher the edge so it's not sharp. If you don't feel comfortable doing this then take it to a qualified shop. If you take to much it could be expensive!!

You don't need a lot of torque on these screws. The seals will keep pressure on them so they don't back out. Over tightening them will distort the flange and cause a leak.

I feel for you as I've had issues with these in the past but this had been the best way I know.

 

Thanks for the advice but of course the heads have been milled and a thinner head gasket was used. HPI rebuilt the 58mm t/b. I don't think I put lube on the gaskets when I installed them. I'm thinking about re-torquing the screws to see if they did loosen up a bit but that would be too lucky for me.

 

I have an HPI 55mm TBI and ended up taking .015" from each side of my intake to get the necessary clearance. You need at least .005" from the manifold spigot to the head. I set mine at .010". My heads were milled .045" and I'm using .040" MLS gasket.
If you have not removed any material from the intake, your probably leaking from a poor fit. Don't ask how i know that. If you have to work to get the bolts started you are to tight and the seals are not able to make up the difference.