Replacing intake gaskets (DIY TUTORIAL)

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*My experience* has been that when replacing the intake seals with the James blue gaskets (with the flange) is that when you replace with those, without rotating the engine, it is very tricky to get them in place. When I did it (without rotating the engine) the fit was very tight and I could not verify the seals were in correctly. So, I went back to the stock seals.

The flanges should not bend unless you over torque them, regardless of seal type/brand, etc. I just did them snug/finger tight with a touch of blue locktite on the threads (probably unnecessary) to prevent the nuts and bolts from backing off due to engine vibration.
 
The flanges will bend under torque specified in service manual.

So, you're saying the flanges are designed to bend???

Or that the torque specified in the service manual is incorrect???

Normally, I'd doubt the service manual to be incorrect, but the whole oil drain plug torque spec fiasco is giving me second thoughts.
 
The flanges will not bend with correct size gaskets at any torque because of correct size gasket are thin enough to be compressed by flange. Flange will rest on engine surface with correct size gasket. Blue gasket is thicker and flange bend around the blue gasket before you torque it to specified force. Flange will rest on blue gasket without touching engine surface.
 
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Did you rotate your engine to install the new seals and torque the intake fasteners ? If so, how did you get a torque wrench in there to do that?

Next time, I'll probably just rotate the engine and do base gaskets, PCV grommets, and all the other items that are more easily done during a rotate.
 
I did not rotate engine to replace gaskets. I used toque wrench to feel torque and then replicated torque by memory with conventional wrench. There is no space for torque wrench. Currently I use custom flanges and I torqued them just to be snug enough without torque wrench.
 
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If you decide to get a set of James, pick up a set of Harley ones as well. When you get the manifold off and see how the sealing works, you’ll see that the stockers fill be fine.

If you’re not going to rotate the engine, good luck getting the James gaskets in. I’m sure some people have, but it was very tricky for me due to space constraints. I didn’t want to do it twice, so I used a set of stock Harley seals.

On my Sportster, sure why not... or if I had some damage to the sealing surfaces, then yeah James may be the way to go.


Best in mind that the James seals i’m referring to are the blue one with the “flange”. I think they make a stock style one as well, which is probably fine, and is probably what the shop will have instead of stock Harley seals. I don’t think the indy shops can get parts from Harley.

https://goo.gl/images/KSJ12q
 
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