Hello all! Im new as a member but not new to all the helpful info in here!..........I have a problem I need some help with.......I recently purchased a shortblock from RPM Ron's in Utah and a pair of reman. heads from Clearwater. After assembling the engine and filling with water, I had a leak at the back of the engine. Apparently the intake manifold did not seat properly. Upon inspection, the rear of the manifold has some side-to-side play while the front seems just fine. Any ideas, suggestions, remedies? <img src="/forums/images/graemlins/zombie.gif" alt="" />
1991 Montero LS 6G72 12v SOHC 181ci.

If the manifold is moving then it's not attached correctly. Once it's bolted down it should be rock solid. Did you use the proper gaskets & tighten the manifold to the proper torque?

Yes I did according to the manual. One other thing I should have mentioned that doesn't make sense-- I noticed after inspecting the gaskets that it appears that most of the force/contact was applied to the upper edge of the gasket and less to the lower edge. This would seem to suggest that possibly the surface angles on the heads and the manifold surface angles could be off. The heads are new reman. and the manifold is original. I used the manifold on a used JDM motor and it sealed just fine. I'll re-inspect and make sure the manifold is actually seating properly

It would not surprise me if the block had been decked as well as the heads changing the relationship of the port faces on the intake surface. You may need to face the intake and with it all in the truck, trying to measure it, all I can say is good luck.
Reman parts suck.

so your saying there is a high spot in the middle and it rocks side to side ?

If the above question wrt a high spot in the middle of the lower intake is the issue, I've noted this warp a few times. It's common on 3.0L engines and can be resolved by milling the lower intake head flanges. I have pictures on my home PC, but no access to them now.

You can check the flanges with a straightedge or on a flat surface like a kitchen countertop. If the lower intake is badly warped, it should also be checked to make certain the top flange is straight..... it may need to be milled also.

The first thing to do is to see what's warped - heads or lower intake. Also, make sure that the lower intake stud threads will allow full torque-down of the nuts..... if not, an extra washer can be used to take up slack. Also, tighten the nuts as you would a head bolt sequence, starting in the middle of the stud pattern and working in a circle toward the ends in steps of increasing torque value until you reach the prescribed limit.

Finally, I would suggest using Permatex Copper Spray-A-Gasket.... 2 coats on the head flanges, gaskets (both sides) and the lower intake flanges.

Frank

Thanks guys........ya'll have given me a place to start........I'll check it all out and let ya know.....Thanks again!! <img src="/forums/images/graemlins/kewl.gif" alt="" />