Head gasket/Intake Manifold removal guide with details needed!!!!!

[Dr.Noisewater]

The topic says it all. I have been searching the web all day long and I have only found vague descriptions. I'm new to NICO but I know how forums work and I just cannot seem to find any descriptive intake manifold guides. Here is some background info for and readers: I own a 1991 240sx Fastback S13 KA24DE completely stock and in need of some work to say the least! The previous owners really neglected this great car. I beleive the head gasket is blown or the head is cracked!!!!!! Tell me if im wrong but do I not have to remove the Intake manifold and the Exhaust manifold to open the rocker cover and get down to the head gasket????? I know I can do it I just need some help. I cannot find a Head gasket repair thread or anything like that just engine removal stuff. HELP GUYS I'm so ready to get this project back on the road literally!!!!

[vancouverbc]

look up intake and engine in tutorials. you will really have to search to find the details you are looking for though. i have not seen any formal tutorials on this. service manual is in my signature
Modified by vancouverbc at 10:34 PM 6/10/2009

[Dr.Noisewater]

Thanks for your help but I have read through both the Intake and Exhaust manifold tutorials they kind of skip all the issues I have!!! Just my luck. I have a Chilton Repair Manual but is so damn vague. I will try to look through your signature. If you have any tips for trouble shooting my issue let me know. I think its the head/head gasket because my exhaust is burning white smoke... so does everyone agree?

[PapaSmurf2k3]

http://www.240sxtech.com/

You should find something in there.

NO, you do NOT have to pull the manifolds off to do a headgasket. You might have to unbolt the exhaust at some point, and disconnect the intake tube from the intake manifold, as wall as some vacuum lines, but you can pull the head while leaving the manifolds on.

If you think its cracked somewhere, you can pull the valve cover off no problem, and see if any cracks are staring you in the face. Just don't overtighten the bolts when putting them back in, that aluminum likes to strip.

[Dr.Noisewater]

Thanks PapaSmurf but that site did not help ether. Now I also smell exhaust in the cabin while driving so I think I should inspect the exhaust manifold for cracks or blown gaskets. Do u agree? Thats while I decided to take off both manifolds and check all the gaskets I can since they are cheap and probably have never been changed like almost everything in the car. Which brings me to another question I do plan to Turbo my KA so I looked into different types of head gaskets and I'm not sure which one to use. MSL VS. Solid Copper is what I think I have narrowed it down to. THANKS guys for all the help. I'm on my computer in my garage messing with my 240 now!

[PapaSmurf2k3]

If you have any exhaust leaks, you should be able to hear them.

But yeah, it never hurts to replace the gaskets. Just pull the manifolds. I replaced my head gasket with a stock unit when turboing my car. Stock is pretty darn good, and also acts sort of like a fuse if anything were to go wrong, you'll blow the $50 headgasket as opposed to blowing something else more expensive. Anyway, here is how you change the headgasket:

Pull the valve cover(optional like I said) remove intake and exhaust manifolds- they can be a PITA sometimesremove the cams and upper timing sprocket- make sure you put your engine at TDC Compression stroke before doing any of this, and mark up your sprockets with each chain so you get your cam timing right when putting it all back together

you also might have to remove the vacuum distribution block off the back of the head, as well as the EGR tube (not sure, I removed my EGR), and the engine grounds.Clear any wiring out of the way (disconnect it from anything and swing the harness to the side)Now you can start removing the head boltsTake them out, and pull the head off... try not to pry it too much with anything thin... as the head is aluminum and is easily scratched/scuffedremove headclean spilled coolant from cylinder boresreplace gasketinstall is pretty much reverse of removal. Use new head bolts or upgrade to re-usable ARP hardware (I strongly suggest this especially if you are going turbo).

Its pretty well outlined in the FSM, which is available free online... There is a link in my sig.

[Dr.Noisewater]

Thanks for the tips. I'm kinda stuck on two things at the moment. I have the exhaust mani off the head slighty I cannot get the small metal pipe that connects to the exhaust pipe under the car off. I believe its the EGR connection. Next I have slowly been removing and labeling components on the intake mani. I have removed the throttle cable and the in/out fuel lines and removed the air intake from the throttle body. However I am stuck on how to remove the whole intake mani from the head. Some of the bolts seem very difficult to remove. Any more help will be much appreciated guys!

[PapaSmurf2k3]

Invest in a swivel socket and remove all the bolts that are on the head. There is 1 PITA area though, and that's on the left had side (IIRC). Its a stud that comes out of the head and you have to pull the mani away from the head, then up... its a b****.

Yeah, that tube going to your exhaust is the EGR pipe... good luck trying to remove it... it is also a PITA. You'll probably be best off just removing the EGR valve from the intake manifold as opposed to trying to loosen that pipe.

[Dr.Noisewater]

Okay well I ghetto rigged some sockets and removed all the bolts connecting the intake mani to the head. However it still seems to very firmly held on. I'm not so sure by what any ideas??? Oh and as far as the EGR Valve I have not messed with that yet could thats what is keeping me from removing both my intake and exhaust mani???

[PapaSmurf2k3]

the intake mani should at least wiggle on the head... make sure you have all the bolts out... it might be stuck, try hitting it with a hammer a little.

[ob1]

I have the same problem getting ready to change my headgasket. Do you have to remove the intake mani?

[Dr.Noisewater]

I was told you do not have to BUT I am just for a little fixer uper since I want to replace any messed up gaskets along with my head.