someotherguy
I'm Awesome
1994 TBI 5.7 intake gaskets
Written 02-10-2011
At 158K miles or so the intake gaskets on my 1994 C2500LD with the 5.7 TBI engine failed. Not an outright failure but obvious signs of seepage at the front of the driver's side head. Not wanting to let it go until the problem got worse, I tore into it for replacement...here's a write-up. It's not meant to be a literal step-by-step; it assumes you have some basic mechanical experience and tools and know your way around under the hood. DISCLAIMER: I wrote this in a hurry so if there's mistakes, don't sue me! But please email me and let me know. Thanks, and hope you find it useful!
Parts/supplies needed: gaskets - intake, TBI, EGR, thermostat, distributor; RTV silicone (I like Permatex black), new 195F thermostat (Stant or Robertshaw), fuel supply/return line O-rings, coolant, brake parts cleaner, PB Blaster, lots of paper towels, wide masking tape, scrap cardboard, oil and filter for changing oil after job is finished. Optional: spray paint and valve cover gaskets. This is also a great time to do cap & rotor, PCV valve, CTS, etc. if it's been a while!
I tried to take notes during the job for what all tools I used. This will be a mostly complete list: siphon hose, drain pan, pliers, #1/#2 flat screwdrivers, 3/8 flex handle ratchet, short & long extensions, deep sockets: 9/16; shallow sockets: 10mm, 1/2, 9/16, 5/8; combo wrenches: 10mm, 19mm, 5/8, 11/16, 13/16; 16mm flare wrench, small hammer, wood block, 7/32 nutdriver, 9/16 distributor wrench, gasket scraper, parts cleaning brush, timing light. A digital camera and notebook computer come in VERY handy for taking pictures along the way, and reviewing later during re-assembly.
I started by using a cheap siphon hose snaked all the way down the radiator tank to remove several gallons of coolant, to avoid making a big mess when I pull the intake. I was working inside and couldn't have any coolant puddles on the floor for my pets to get at. Next up are pics of everything as it comes apart, for reference when re-assembling. Everything is in the stock configuration except for the extra vacuum line T'd off the PCV connection for my vacuum gauge, and the brass fuel pressure test fitting at the rear of the TBI on the supply line.
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